Chevrolet - Trailblazer 2wd V8 - Workshop Manual - 2003 - 2003

Page 892 Body Control Module (BCM) C1 Part 2 Page 8333 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 414 Page 12965 Page 10368 Abbreviations And Meanings Part 21 Page 5324 Disclaimer Page 10006 Page 3135 2. Install the spark plugs to the engine. Tighten the spark plugs to 18 Nm (13 lb ft). 3. Install the ignition coils. Refer to Ignition Coil Replacement. Page 10329 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 9393 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 13909 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 10641 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 12326 2. Remove the 3 bolts that retain the head restraint retractor assembly to the seat back frame. 3. Partially remove the head restraint retractor assembly from the frame. 4. Remove the release cable by sliding the cable retainer over to the large access hole and removing the cable from the head restraint retractor assembly. 5. Remove the retractor assembly from the seat back frame. INSTALLATION PROCEDURE Page 5241 For vehicles repaired under warranty, use the table. Disclaimer Page 4149 Splice Pack SP205 Part 1 Page 6731 For vehicles repaired under warranty, use the table. Disclaimer Recall - Flasher Relay Module Replacement Technical Service Bulletin # 05044 Date: 050728 Recall - Flasher Relay Module Replacement Bulletin No.: 05044 Date: July 28, 2005 SAFETY Subject: 05010 - INTERMITTENT INCORRECT TURN SIGNAL OPERATION Models: 2004 BUICK RAINIER 2003-2004 CHEVROLET TRAILBLAZER, TRAILBLAZER EXT 2003-2004 GMC ENVOY, ENVOY XL 2004 GMC ENVOY XUV 2003-2004 OLDSMOBILE BRAVADA Condition General Motors has decided that a detect, which relates to motor vehicle safety, exists in certain 2004 Buick Rainier and GMC Envoy XUV; 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles. Some of these vehicles have an intermittent condition in which the turn signals may not operate as designed. Material build up on the flasher relay may cause the turn signals to flash on both sides of the vehicle when activated similar to hazard warning flashers, or they may illuminate and remain illuminated instead of flashing. The instrument panel would indicate the incorrect operation if this were to occur. Incorrect operation of the turn signal indicator could fail to warn others of the driver's intentions and could lead to a vehicle crash. Correction Dealers are to replace the flasher relay module. Vehicles Involved Page 7104 C307 Part 1 Page 12376 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Part 1 Page 2922 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 5550 Shift Cable: Adjustments Automatic Transmission Range Selector Cable Adjustment Adjustment Procedure 1. Ensure that the range selector cable is not restricted. 2. Ensure that the floor Shift control is in the PARK position. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Disconnect the range selector cable (4) from the range selector lever ball stud (6). 5. Ensure that the range selector lever is in the mechanical PARK position. (Rotate the range selector lever fully clockwise). 6. Release the locking tab (1) 7. Slide the secondary lock cover (1) to the side 8. Carefully squeeze the locking tabs (2) together to disengage the primary lock. Page 10346 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 631 Front Passenger Door Module (FPDM) - C2 Part 2 Page 4720 1. Install the fuel filler pipe to the vehicle. 2. Install the push pin fastener (5). 3. Uncap the fuel tank. 4. Install the fuel hose (2) to the tank. 5. Tighten the fuel fill hose clamp (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the clamp to 2.5 N.m (22 lb in). 6. Install the fuel fill pipe ground strap bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). 7. Lower the vehicle. Page 6272 12. Remove the brake pad retaining clip from the brake caliper. 13. Remove all foreign material from the brake caliper using denatured alcohol. Installation Procedure Important: When installing new brake pads, DO NOT reuse the old retaining clips for the brake pad. Use only NEW brake pad retaining clips. 1. Install the brake pad retaining clips to the brake caliper mounting bracket. 2. Install the brake pad retaining clip to the brake caliper. Page 9686 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 1148 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lift up on the front edge of the door lock and side window switch (1) in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. Remove the electrical connector (2) from the memory seat switch. 4. Remove the memory seat switch from the lock and door lock and side window switch (1). INSTALLATION PROCEDURE Body - Rattle Under Hood Hood Support Rod: All Technical Service Bulletins Body - Rattle Under Hood Bulletin No.: 04-08-63-005 Date: June 15, 2004 TECHNICAL Subject: Rattle Noise Under Hood (Reposition Hood Prop Rod) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on a slight buzz or rattle noise coming from under the hood. This noise could be mistaken for a unusual engine noise. Cause The hood prop rod may be making contact with the fan shroud. Correction Adjust the hood prop rod. 1. Support the hood. 2. Make sure the plastic prop rod pivot block is fully seated into the radiator support before making the adjustment. 3. Adjust the prop rod by bending the rod at the point of contact. Refer to the arrow in the illustration above. There should be approximately 10 mm (3/8 in) between the prop rod and the shroud. Warranty Information For vehicles repaired under warranty, use the table. Page 890 Body Control Module (BCM) C1 Part 2 Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 6958 Fuse Block - Rear C2 Part 6 Page 5161 For vehicles repaired under warranty, use the table. Disclaimer Page 9412 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 5543 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12536 Abbreviations And Meanings Part 4 Page 7123 C600 Part 2 C700 Part 1 Page 3503 Abbreviations And Meanings Part 20 Page 2907 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 4824 Ignition Coil 4 Page 141 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 1393 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. 1. Install the CKP sensor into the engine block. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 10762 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 9 Page 473 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 3072 Disclaimer Page 8363 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 13898 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 4150 Splice Pack SP205 Part 2 Ignition System - MIL ON/Misfire DTC's In Wet Weather Ignition Coil: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 3446 Diagram Information and Instructions Door Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 6800 Abbreviations And Meanings Part 4 Page 12907 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 1167 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure Page 13877 Page 9211 Steps 1-2 Page 7537 8. Release the tabs that retain the junction block to the block base. 9. Remove the junction block from the block base. 10. Disconnect the instrument panel harness connector (1) from the junction block. 11. Disconnect the mobile telephone harness connector (1) from the junction block. Page 12108 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 13190 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 4. Install the RF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 3. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. Page 8323 40.1. Install the ring terminal (black wire) to ground G103 (1), located on the right side inner tender. 40.2. Route the pump wiring harness along the existing right side forward lamp harness. 40.3. Connect the electrical connectors to the coolant bypass valve (1) and auxiliary heater pump (2). 40.4. Position the relays onto the inner wheelhouse panel near the rear of the engine compartment. Page 2347 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 4535 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the fuel pressure service connection cap. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Install the fuel tank shield if removed. Locations Fuel Tank Emissions - DTC P0440/P0455/P0442 (EVAP) Diagnostics Fuel Filler Neck: All Technical Service Bulletins Emissions - DTC P0440/P0455/P0442 (EVAP) Diagnostics Bulletin No.: 05-06-04-014A Date: March 21, 2005 INFORMATION Subject: Diagnostic Aids for Diagnostic Trouble Codes P0440, P0455 and/or P0442 - Evaporative Emission (EVAP) System Leak Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada with 83 Liter (22 Gallon) or 96 Liter (25 Gallon) Fuel Tanks Supercede: This bulletin is being revised to remove the 2005 model year. Please discard Corporate Bulletin Number 05-06-04-014 (Section 06 - Engine/Propulsion System). This bulletin is being published to aid technicians in the diagnosis of DTCs P0440, P0455 and/or P0442. It is possible that a fracture as small as 0.508 mm (0.020 in) may be found in the fuel tank filler neck, causing a DTC P0440, P0455 and/or P0442 to set. Due to the location above the liquid fuel level, this small fracture will not cause a visible fluid leak. The technician should pay particular attention to the fuel tank filler neck area while performing the smoke test outlined in SI. Refer to the appropriate diagnostic information for P0440, P0455 and/or P0442 in SI. When performing the smoke test outlined in SI, it may be necessary for the technician to manipulate the fuel tank filler neck in order to see smoke escaping from this minute fracture. Disclaimer Page 13069 Miniwedge (Door Jamb Switch) - RF Locations Fuel Tank Pressure Sensor: Locations Fuel Tank Page 49 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 7530 Application Table Part 4 Location View Page 8195 1. Install the mode actuator (3). Note: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws to the mode actuator (3). Tighten Tighten the screws to 1.9 N.m (18 lb in). 3. Install the air outlet duct. Refer to Air Outlet Duct Replacement - Floor, LH in Heating, Ventilation, and Air Conditioning. Disclaimer Page 2714 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Above -18° C (0° F) ......................................... .......................................................................................................................... 10W-30, 5W-30 (preferred) Below -29° C (-20° F) ................................................................................................................................................. 5W-30 synthetic (preferred) , 0W-30 Page 129 Page 3216 Disclaimer Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Page 12116 Page 2795 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 6210 Abbreviations And Meanings Part 9 Page 13200 Disclaimer Page 6849 Page 2238 Fuse Block - Underhood C2 Part 5 Page 355 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 8268 1. Position the air outlet face down at the housing opening. 2. Position the right side of the air outlet below the housing retaining pin. 3. Seat the right side of the air outlet to the housing retaining pin by lifting upward. 4. Seat the left side of the air outlet to the housing retaining pin. 5. Rotate the air outlet upward past the detent position. 6. Adjust the air outlet to the original position. Entertainment System - DVD Monitor Display Inoperative DVD Player: Customer Interest Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Page 7450 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 3537 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). 7. Disconnect the body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. Page 3867 Page 3346 12. Disconnect the radiator side panels from the shroud (1). 13. Remove the radiator. 14. Remove the bolts retaining the condenser to the radiator. Installation Procedure 1. Install the condenser to the radiator. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the bolts retaining the condenser to the radiator. Tighten the bolts to 28 Nm (21 ft. lbs.). 3. Install the radiator. 4. Install the cooling fan and shroud. 5. Raise the vehicle. Page 4239 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 13834 Turn Signal/Hazard Flasher Module Part 2 Page 10901 Body Control Module (BCM) C1 Part 2 Page 9650 Page 12419 5. Install the inflatable side impact module to the seat back frame with 2 screws (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the side impact module screws to 9 N.m (80 lb in). 6. Install the seat belt and retractor assembly. 7. Install the lumbar assembly. 8. Install the front seat back panel. 9. Install the seat back cover and pad. 10. Install the front seat back. 11. Install the seat trim panel. 12. Install the seat assembly to the vehicle. Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear bumper fascia. 2. Using a small flat-bladed tool, apply pressure at two upper locations and two lower locations to release the retainers on the pressure relief valve. 3. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Install the rear bumper fascia. Specifications Timing Chain Guide: Specifications Timing Chain Tensioner Guide Bolt 124 inch lbs. Timing Chain Tensioner Shoe Bolt 18 ft. lbs. Timing Chain Top Guide Bolt 89 inch lbs. Page 9150 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 3890 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 894 Body Control Module (BCM) C3 Part 1 Page 6060 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 7158 8. Release the tabs that retain the junction block to the block base. 9. Remove the junction block from the block base. 10. Disconnect the instrument panel harness connector (1) from the junction block. 11. Disconnect the mobile telephone harness connector (1) from the junction block. Page 6793 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 5742 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Page 9875 Global Positioning System Module: Service and Repair Communication Interface Module Replacement 2 COMMUNICATION INTERFACE MODULE REPLACEMENT (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE 1. Fold and tumble the right second row seat to a cargo position. IMPORTANT: Do not exchange the vehicle communication interface module with other vehicles. Each vehicle communication interface module has a specific station identification (STID) and electronic serial number (ESN). These identification numbers are stored in the General Motors vehicle history files by VIN and used by OnStar(R) and the National Cellular Telephone Network. 2. Remove the protective cover (1) from the vehicle communication interface module (VCIM). 3. Remove the VCIM from the bracket by releasing the retaining tab (1). 4. Remove the electrical connectors from the VCIM. 5. Remove the VCIM from the vehicle. INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. 2. Position the VCIM near the mounting location. Page 6465 2. Fill the master cylinder reservoir with brake fluid. 3. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding. 4. Install the master cylinder to the vehicle. Page 2701 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the A/C line bracket nut. 2. Remove the A/C line bracket from the oil level indicator tube stud. 3. Disconnect the 02 sensor electrical connector from the oil level indicator bracket. 4. Remove the oil level indicator tube stud. 5. Pull the indicator out of the tube. 6. Pull the tube out of the block. Installation Procedure 1. Install the oil level indicator tube into the engine block. Page 6818 Abbreviations And Meanings Part 22 Page 9163 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 10141 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 7580 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 4605 Fuel Injector 4 Page 6884 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 9026 Seat Belt: Service and Repair Seat Belt Replacement - Rear REMOVAL PROCEDURE 1. Remove the rear seat belt upper guide shoulder bolt. 2. Remove the rear quarter upper trim, left or right side. 3. Remove the lower seat belt anchor bolt cover. 4. Remove the rear seat belt floor anchor bolt. 5. Remove the rear quarter lower trim, left or right side. 6. Remove the bolt that retains the rear seat belt retractor assembly to the body. 7. Remove the rear seat belt retractor assembly from the vehicle. INSTALLATION PROCEDURE 1. Position the rear seat belt retractor assembly to the vehicle. 2. Install the bolts which retain the rear seat belt retractor assembly to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat belt retractor bolts to 70 N.m (52 lb ft). 3. Install the rear quarter lower trim, left or right side. 4. Install the rear seat belt floor anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten Tighten the rear seat belt floor anchor bolt to 70 N.m (52 lb ft). Page 10286 Speaker: Service and Repair Speaker Replacement - Front Door SPEAKER REPLACEMENT - FRONT DOOR REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the speaker electrical connector. 3. Remove the 3 speaker retaining bolts. 4. Remove the speaker from the door. INSTALLATION PROCEDURE 1. Install the speaker to the door. 2. Install the 3 speaker retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the speaker electrical connector. 4. Install the front door trim panel. Page 8159 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 746 For vehicles repaired under warranty, use the table. Disclaimer Page 12180 Abbreviations And Meanings Part 25 Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 10150 Diagnostic Tips Review Table Page 7840 5. Disconnect the ABS wheel speed sensor wiring harness from the upper control arm. 6. Remove the upper control arm mounting bolts. 7. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper control arm mounting bolts. Tighten the upper control arm mounting bolts to 150 Nm (111 ft. lbs.). Page 11419 5. Position the bellcrank (1) at a 45 degree angle (2) compared to the vertical edge of the window side sheet metal (4). 6. Using the body side power window switches (1 or 2) at the overhead console, push the switch in order to position the bellcrank at a 45 degree angle to the sheet metal flange. 7. Install the screw connecting the window bracket to the actuator arm. IMPORTANT: The bellcrank arm (1) needs to be at a 45 degree angle (2) parallel to the sheet metal flange (4) prior to securing the actuator arm screw. Tighten Page 13148 Abbreviations And Meanings Part 20 Page 12161 Abbreviations And Meanings Part 6 Page 13564 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition contained in this bulletin are to be submitted by August 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Valve Lash Adjuster Replacement Tools Required - J 36660-A Torque Angle Meter - J 44222 Camshaft Sprocket Holding Tool Removal Procedure 1. Remove the camshaft cover. 2. Remove the exhaust and the intake sprocket bolts. 3. Install the J44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components. 4. Carefully move the sprockets with the timing chain off of the camshafts. Important: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed. 5. Remove the camshaft cap bolts. 6. Remove the camshaft caps. Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Specifications Console: Specifications Fastener Tightening Specifications Page 10200 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 13922 Conversion - English/Metric Part 2 Page 557 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 3587 Powertrain Control Module (PCM) C3 Part 2 Page 11861 Door Module: Electrical Diagrams Door Control Module Diagram 1 Page 3015 20. Remove the J 44221. 21. The dark lines (1) on the chain should be aligned with the marks on the sprockets as shown. 22. Install the top chain guide. 23. Add Threadlock GM P/N 12345496 on the top chain guide bolt threads. 24. Install the top chain guide bolts. Tighten the top chain guide bolts to 10 Nm (89 ft. lbs.). 25. Install the engine front cover. 26. Install the camshaft cover. Page 11662 10. Install the auxiliary air conditioning duct to the vehicle with the bolt. Tighten the auxiliary air conditioning duct bolt to 10 N.m (88 lb in). 11. Connect the coax cable (1) to the navigation antenna, if equipped. 12. Connect the rain sensor electrical connector (2), if equipped. 13. Connect the inside rear view mirror electrical connector (3). 14. Install the windshield rearview mirror wire harness cover. 15. Install the video display. 16. If equipped, install the front and rear overhead console. 17. Install the windshield garnish moldings. 18. Install the center pillar trim panels. 19. Install the front side door sill plates. 20. Install the right sound insulator. 21. Connect the cellular antenna coax cable to the inner coupling on the left body side window. 22. Install the headliner harness to the left third pillar. 23. Install the headliner harness to the floor studs. 24. Install the ground terminals and the ground bolt to the left center pillar. Tighten the ground bolt to 10 N.m (88 lb in). Page 766 service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers, possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in Page 6678 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 6177 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 7311 Application Table Part 2 Page 5148 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector.Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON transmission fluid. Page 4317 10. With an upward motion, remove the BCM (1) from the rear electrical center. INSTALLATION PROCEDURE 1. Index the slots on the BCM (1) to the rear electrical center. 2. Using a downward motion, install the BCM to the rear electrical center. Page 11632 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the grille. 6. Remove sensor bracket from bumper. 7. Remove the Connector Position Assurance (CPA) from both (2) electronic frontal sensor (EFS) connectors. IMPORTANT: This vehicle is equipped with two inflatable restraint electronic frontal sensors (EFS). When performing this procedure be sure to include both EFS's. 8. Disconnect both EFS connectors. Zone 2 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 6890 Abbreviations And Meanings Part 5 Page 2507 Camshaft: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure 1. Remove the drive belt. 2. Remove the 3 power steering pump bolts and move the pump out of the way. 3. Disconnect the camshaft position actuator solenoid electrical connector. 4. Remove the camshaft position actuator solenoid retaining bolt (3). 5. Remove the camshaft position actuator solenoid (2) from the engine block. 6. Clean debris from the hole (1). Installation Procedure 1. Lubricate the hole (1) with engine oil. 2. Install the camshaft position actuator solenoid (2) and bolt (3). Tighten the bolt to 10 Nm (89 in. lbs.). 3. Connect the camshaft position actuator solenoid electrical connector. 4. Install the power steering pump and bolts. 5. Install the drive belt. Page 1450 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 9844 Garage Door Opener Transmitter: Description and Operation GARAGE DOOR OPENER DESCRIPTION AND OPERATION The garage door opener is located in the overhead console. The valet switch provides battery voltage to the garage door opener. If battery voltage is lost due to a condition such as a dead battery, the garage door opener unit relies on the non-servicable internal power backup supply. The unit is programmed using the customer's hand-held transmitters for the garage doors, electric entrance gates, or lighting and security systems. The garage door opener is rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the garage door opener to change every time the garage door opener is used within operating range of the receiver. When the receiver and the garage door opener are initially programmed together, a code is established, a new code is created for every new transmission. The software in the receiver recognizes the garage door opener and accepts the new code. The garage door opener is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, call HomeLink(TM) at 1-800-355-3515. The garage door opener is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of radio frequency interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters, refer to Garage Door Opener Programming - Universal. The garage door opener has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 garage door openers, security gates, and lighting systems. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Battery voltage is provided to the garage door opener from the IGN SEN fuse in the IP fuse block. The garage door opener is grounded through G400. Inadvertent power is supplied from the body control module (BCM). Locations Engine, Left Front Page 331 Page 11259 8. Open the hood and install the prop rod. 9. Install the left and right adjustable rubber bumpers and adjust them all the way down. 10. Close the hood and verify adjustment. The bumpers are required to make contact with the hood. Adjust if necessary. 11. Apply white lithium grease to the bottom of the V on the latch. Refer to illustration above. 12. Verify the final adjustment by grabbing the hood and jiggling it up and down. If a rattle is heard, perform the procedure again. 13. Install the grille. Refer to Grille Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1828 3. Measure the D height by measuring the distance between the jounce bumper bracket and the top of the rear axle tube. 4. Repeat the jouncing operation and measurement 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true D height dimension is the average of the highest and lowest measurements. Cross vehicle D heights should be within 12 mm (0.5 inch) for vehicles equipped with coil springs, vehicles equipped with air suspension should be within 8 mm (0.3 inch). 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging rear suspension. ^ Collision damage. Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 10819 Page 1368 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. 2. Install the APP sensor retaining fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 3468 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 6377 ^ If the brake pipe does NOT have the tooling mark (2), proceed to the next step of the inspection. 6. Clean and remove any dirt from the left front brake pipe and flare nut (3) where it connects to the ABS modulator under the vehicle. The left front pipe is on the top row and closest to the center of the vehicle. 7. Carefully inspect the brake pipe where the pipe goes into the flare nut for the same type of tooling mark (1) as shown above. The mark may be located at any point around the circumference of the pipe and a mirror flashlight may be required to see it. There will NOT be any of the spiral lines or grooves (2) in the tooling mark. ^ If the tooling mark IS present, then the brake pipe does NOT need to be replaced. Lower the vehicle and install the GM Recall Identification Label. ^ If the tooling mark is NOT present, then the brake pipe must be replaced. Proceed to the Replacement procedure, below. Replacement Procedure This replacement procedure should only be performed if the results of the Inspection procedure indicated that the brake pipe needed to be replaced. Bleeding of the hydraulic system is done using a pressure bleeder and is limited to the left front brake. This pressure bleeding procedure is a shortened version of the full vehicle procedure found in the Service Manual. As a result, the labor time included in this recall for bleeding the brake system is less. Important To avoid unnecessary brake fluid loss, have the new brake pipe ready to install before you begin removing the old pipe. 1. Disconnect the brake pipe (1) from the left front caliper brake hose fitting. 2. From underneath the vehicle, disconnect the other end of the brake pipe (1) from the ABS modulator located on the inboard side of the left frame rail. 3. Disconnect the pipe from the lower retainers on the frame. 4. Disconnect the pipe from the upper retainer on the frame. Page 12454 2. Install the small loop (1) onto the rear seat cushion latch (2). 3. Install the strap through the opening in the seat pan. 4. Install the rear-seat cushion cover and the pad. 5. Install the rear seat cushion assembly to the vehicle. Seat Cushion Pull Strap Replacement - Rear No. 1 SEAT CUSHION PULL STRAP REPLACEMENT - REAR NO. 1 (TRAILBLAZER, ENVOY, BRAVADA) REMOVAL PROCEDURE 1. Remove the rear seat cushion assembly from the vehicle. 2. Remove the rear-seat cushion cover and the pad. 3. Remove the strap (1) from the rear seat cushion latch (2). INSTALLATION PROCEDURE Page 19 Page 3491 Abbreviations And Meanings Part 8 Page 10411 Page 134 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 2860 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Low or No Oil Pressure The following can cause low or no oil pressure: * Low oil level-fill to the full mark on the oil level indicator. * Slow idle speed * Incorrect or malfunctioning oil pressure switch- replace the oil pressure switch. * Incorrect or malfunctioning oil pressure gage- replace the oil pressure gage. * Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature. - Install new oil if it is diluted. * The oil pump is worn or dirty-clean or replace the oil pump. * The oil filter is plugged-replace the oil filter. * The oil pickup screen is loose or plugged- replace the oil pickup screen. * A hole in the oil pickup tube-replace the oil pickup tube. * Excessive bearing clearance-replace the bearings. * Cracked, porous, or plugged oil galleries-repair or replace the engine block. * The gallery plugs are missing or improperly installed-install or repair as necessary. * The pressure regulator valve is stuck. Check the pressure regulator valve for sticking in the bore. - Check the bore for scoring and burrs. * The camshaft is worn or poorly machined- replace the camshaft. * Worn valve guides-repair as needed. Oil Pressure Testing Tools Required J 21867 Pressure Gauge and Hose - J 42907 Oil Pressure Tester Adapter If the vehicle has low oil pressure perform the following tests. 1. Check the oil level. 2. Raise the vehicle and remove the oil filter. 3. Assemble the plunger valve in the large hole of J42907 (1) base and the hose in the small hole of J42907 (1) base. Connect the J21867 (2) to the end of the hose. 4. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve itself. 5. Install J42907 (1) on the filter mounting pad. 6. Start the engine and check the overall oil pressure and the oil pressure switch. The engine should be at operating temperature before checking the oil pressure. The oil pressure should be approximately 85 kPa (12 psi) at 1200 rpm using 5W30 engine oil. 7. If adequate oil pressure is indicated, check the oil pressure switch. 8. If a low reading is indicated, press the valve on the tester base to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading while pressing the Page 3880 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 13553 service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers, possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in Page 7249 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 12169 Abbreviations And Meanings Part 14 Page 7160 6. Connect the mobile telephone harness connector (1) to the junction block. 7. Connect the instrument panel harness connector (1) to the block base. 8. Install the junction block to the block base. Ensure that the retaining tabs are fully seated. Page 8903 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the EFS connectors to both (2) EFS's. 3. Install the CPAs to both EFS connectors. 4. Install sensor bracket to bumper. 5. Install the grille. 6. Install the SIR fuse into the fuse block (1) located in the underhood fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 1. Remove the key from the ignition. Page 2837 Oil Pressure Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Connector Views License Plate Lamp: Connector Views License Lamp - Left Page 9456 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 359 Labor Time Information Page 6194 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Locations Accelerator Page 5247 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 426 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 12111 Page 8336 Page 226 Page 3516 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Recall 04V046000: Erratic Wiper Operation Wiper Control Module: Recalls Recall 04V046000: Erratic Wiper Operation DEFECT: The windshield wipers on these sport utility vehicles may fail to turn on, unexpectedly stop working, fail to turn off/on by themselves (moisture sensitive wiper system), or the washer pump may operate continuously because water can enter the wiper module and either cause a short circuit or corrosion of components within the module. Driver visibility could be reduced, which could result in a crash. REMEDY: Dealers will cover the windshield wiper module vent hole with a patch. Also, the wiper motor, circuit board, and electrical connector will be inspected for signs of water intrusion and/or corrosion and be replaced as required. The manufacturer has reported that owner notification is expected to begin during the third quarter of 2004. Owners may contact Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Oldsmobile at 1-800-630-6537. A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: All Technical Service Bulletins A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Page 8158 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 7005 Fuse Block: Service and Repair Rear Electrical Center or Junction Block Replacement REAR ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a cargo position. 4. Remove the rear electrical center cover. 5. Remove the battery feed terminal nut (2) from the junction block. 6. Remove the body control module (BCM) from the rear electrical center. 7. Fully loosen the 3 bolts (1) that retain the junction block to the electrical connectors. Page 14013 Page 8880 Ambient Light/Sunload Sensor Assembly Page 6490 1. Install the park brake cables over the fuel tank assembly. 2. Pull the park brake cable through the frame toward the outside of the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the park brake cable retaining nuts to the underbody mounting studs. ^ Tighten the park brake cable retaining nuts to 10 Nm (7 ft. lbs.). 4. Raise the fuel tank the fuel tank to allow access to the rear park brake cable retainer above the fuel tank. 5. Install the rear support bracket for the fuel tank. 6. Remove the pole jack and the block of wood from the fuel tank. Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 5782 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install TCC PWM solenoid retainer. Page 13309 Miniwedge (Door Jamb Switch) - RF Page 10010 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Page 5887 13. The sheared plastic may prevent the bearing cups from pressing into place and thus prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. 2. Assemble 1 bearing cup part way into 1 side of the yoke. 3. Turn the yoke ear toward the bottom. 4. Assemble the cross into the yoke so the trunnion seats freely into the bearing cup. 5. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 6. Assemble the opposite bearing cup part way into the yoke ear. 7. Ensure that the trunnions start straight and true into both bearing cups. 8. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for a free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang-up or binding, stop pressing, and inspect the needle bearings for misalignment in the bearing cup. 9. Press the bearing cup into the yoke until the bearing retainer groove clears the inside of the yoke. Page 9975 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Body - Liftgate Glass Hard to Close Trunk / Liftgate Handle: All Technical Service Bulletins Body - Liftgate Glass Hard to Close File In Section: 08 - Body and Accessories Bulletin No.: 03-08-66-006 Date: June, 2003 TECHNICAL Subject: Lift Gate Glass Hard to Close (Replace Weatherstrip and Shim Handle) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the lift gate glass is hard to close. Cause The weatherstrip may be too stiff and the glass bounces back when closing. Correction Replace the weatherstrip and shim the lift gate window handle. 1. Remove the garnish molding from the lift gate for easy access to the weatherstrip. 2. Remove the lift gate weatherstrip. 3. Install the lift gate glass weatherstrip. 4. Install the garnish molding. 5. Loosen the two nuts that retain the handle and the striker to the glass and install the shim between the glass and the striker. Tighten Tighten the nuts to 6 N.m (53 lb in). Important: Page 10189 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 10392 Steps 3-7 Page 10190 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 678 Power Trunk / Liftgate Control Module: Diagrams Endgate Module (EGM) Endgate Module (EGM) C1 (XUV) Page 12191 Driver Door Module (DDM) - C2 Part 2 Page 4828 Ignition Coil: Service and Repair REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the ignition coil connectors (1) from the ignition coils. 3. Remove the retaining bolts (2) from the ignition coils. 4. Remove the ignition coils (1) from the engine. INSTALLATION PROCEDURE Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Page 7292 Registered And Non-Registered Trademarks Part 2 Page 948 Powertrain Control Module (PCM) C2 Part 3 Page 13476 2. Mask off the desired amount of material to be removed. 3. Open the liftgate glass. Note: Do no damage the applique or the liftgate glass when removing the applique from the liftgate glass. 4. Remove the screws that retain the applique to the liftgate glass. 5. With a flat-bladed tool, carefully remove the applique from the liftgate glass. 6. Remove the CHMSL harness grommet from the roof panel. 7. Disconnect the CHMSL harness connector and remove CHMSL applique from the vehicle. 8. Using a 1/4" die grinder and Scotch-Brite(R) Disc, 3M(R) P/N 07481, remove excess material from the applique. 9. Paint the applique to match. Important: If the original part is used, it is important to seal (clear coat) the edge to protect the clear coat from lifting. 10. Remove the old adhesive from the underside of the applique. 11. Clean the application area of the CHMSL applique with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984, or equivalent, and dry thoroughly using a clean low lint towel or towelette. 12. Apply double-sided adhesive tape, 3M(R) P/N 06397, or equivalent, to the underside of the CHMSL applique. 13. Remove the old adhesive from the liftgate glass. Important: ^ The installation area of the liftgate glass must be clean and dry. Any airborne dust, oils, etc., may contaminate the glass or the applique adhesive, and reduce the bond of the tape. ^ DO NOT use commercial glass or surface cleaners. These may contain petroleum. ^ The glass surface temperature should be no lower than 21°C (70°F) and not exceed 38°C (100°F). 14. Clean the application area of the liftgate glass with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984, or equivalent, and dry thoroughly using a clean low lint towel or towelette. 15. Apply adhesive promoter, P/N 12378555, in Canada, use P/N 88901239, to the liftgate glass surface, completely wetting the applique application Page 6813 Abbreviations And Meanings Part 17 Page 7296 Registered And Non-Registered Trademarks Part 6 Page 7583 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 2938 Abbreviations And Meanings Part 10 Cooling System, A/C - Aluminum Heater Cores/Radiators Radiator: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Page 9133 Page 1260 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 7239 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Press tabs (1) inward and lift to remove the junction block cover. 3. Pull upward on the fuse relay center cover (1) to release the retaining tabs and remove the cover. 4. Note the location and remove the harness end bolts (2) and remove the harness ends from the fuse relay center. 5. Remove the fuse relay center bolts (3) and remove the fuse relay center from the junction block bracket. 6. Pull downward on the wiring harness ends to remove from the bottom of the fuse relay center. Page 3505 Abbreviations And Meanings Part 22 Page 10876 Abbreviations And Meanings Part 12 Service and Repair Extension Housing: Service and Repair Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission mount. 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension O ring seal (3). Installation Procedure 1. Install a new case extension O-ring seal (3). 2. Install the case extension (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (1). ^ Tighten the case extension bolts (1) to 45 Nm (33 ft. lbs.). 4. Install the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 9840 Registered And Non-Registered Trademarks Part 6 Procedures Heated Glass Element: Procedures Bus Bar/Antenna Terminal Repair BUS BAR/ANTENNA TERMINAL REPAIR 1. Buff the repair area with fine steel wool. This will remove the oxide coating formed during window manufacturing. 2. Apply paste-type rosin flux in small quantities to the rear defogger bus bar lead wire, antenna or defogger terminal repair area using a brush. 3. Coat the solder iron tip with solder. Use only enough heat to melt the solder and only enough solder to ensure a complete repair. 4. Apply solder to the bus bar. Draw the soldering iron tip across the fluxed area thinly coating bus bar with solder. 5. Apply a small amount of flux to the underside of the rear defogger bus bar lead wire, antenna or defogger terminal. 6. Apply solder to the underside of the rear defogger bus bar lead wire, antenna or defogger terminal. Draw the soldering iron tip across the fluxed area thinly coating the wire or terminal with solder. Apply heat to the top of the rear defogger bus bar lead wire antenna and/or defogger terminal, causing the solder spot to melt and fuse together. - Use pliers to hold the rear defogger bus bar lead wire, antenna or defogger terminal. - Holding force should not be removed until the solder has solidified. IMPORTANT: Do not overheat the terminal when soldering it to the bus bar. Soldering iron tip temperature should be just enough to melt the solder allowing the solder to run freely. The iron should be in contact with the bus bar for as short a time as possible. 7. Solder the wire or terminal to the bus bar. 8. Wipe off any excess flux. 9. Connect the electrical connector. Grid Line Repair GRID LINE REPAIR TOOLS REQUIRED - J 25070 Heat Gun - Capable of 260°C (500°F) or equivalent - Test Lamp - Rear Window Defogger Repair Kit GM P/N 12346001, Canada P/N 10951643 or equivalent REMOVAL PROCEDURE 1. Disconnect the electrical connector. CAUTION: To avoid personal injury: Do not allow the repair material to come in contact with skin or eyes and avoid breathing vapors. - Do not use near sparks or open flame. 1. Inspect the rear window grid lines. 2. Ensure that the rear window is at room temperature. 3. Inspect the grid line area that you will repair. Verify that the area is dry and free from contaminates. 4. Dampen a cloth with isopropyl alcohol. Use the damp cloth in order to wipe the grid line area clean. INSTALLATION PROCEDURE Page 1194 operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. 2. Install the ECT sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. HVAC System - Manual Air Door Actuator / Motor: Description and Operation HVAC System - Manual HVAC SYSTEM - MANUAL AIR DELIVERY DEFROST ACTUATOR The defrost actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5 volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range.When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. MODE ACTUATOR The mode actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5 volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range.When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. The mode actuator is an electronic stepper motor with feedback potentiometers. The HVAC control module sends signals to the mode door actuator through the mode door control circuit. Zero volts drives the actuator in one direction while 5-volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5-volt reference circuit to the mode actuator. When you select a desired mode setting, logic determines the value of the mode actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the mode door position signal circuit. The motor moves the mode door to the desired position. DEFROST ACTUATOR The defrost actuator operates the same as the mode actuator. The HVAC control module sends signals to the mode door actuator through the defrost door control circuit. Zero volts drives the actuator in one direction while 5-volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5-volt reference circuit to the defrost actuator. When you select a defrost setting, logic determines the value of the defrost actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the defrost door position signal circuit. The motor moves the defrost door to the desired position. AIR TEMPERATURE AIR TEMPERATURE ACTUATOR The air temperature actuators are a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control,5 volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range.When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. Page 12718 Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information Recall - Flasher Relay Module Replacement Technical Service Bulletin # 05044 Date: 050728 Recall - Flasher Relay Module Replacement Bulletin No.: 05044 Date: July 28, 2005 SAFETY Subject: 05010 - INTERMITTENT INCORRECT TURN SIGNAL OPERATION Models: 2004 BUICK RAINIER 2003-2004 CHEVROLET TRAILBLAZER, TRAILBLAZER EXT 2003-2004 GMC ENVOY, ENVOY XL 2004 GMC ENVOY XUV 2003-2004 OLDSMOBILE BRAVADA Condition General Motors has decided that a detect, which relates to motor vehicle safety, exists in certain 2004 Buick Rainier and GMC Envoy XUV; 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles. Some of these vehicles have an intermittent condition in which the turn signals may not operate as designed. Material build up on the flasher relay may cause the turn signals to flash on both sides of the vehicle when activated similar to hazard warning flashers, or they may illuminate and remain illuminated instead of flashing. The instrument panel would indicate the incorrect operation if this were to occur. Incorrect operation of the turn signal indicator could fail to warn others of the driver's intentions and could lead to a vehicle crash. Correction Dealers are to replace the flasher relay module. Vehicles Involved Page 8235 2. Disconnect the electrical connector from the defroster actuator. 3. Remove the screws from the defroster actuator. 4. Remove the defroster actuator. INSTALLATION PROCEDURE 1. Install the defroster actuator. 2. Install the defroster actuator screws. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector to the defroster actuator. 4. Install the IP carrier. Mode Actuator Mode Actuator Replacement Removal Procedure 1. Remove the left side sound insulator screws. 2. Remove the left hand floor duct. Page 11822 Abbreviations And Meanings Part 7 Page 2573 Installation Procedure 1. Install the coolant heater to the engine block. Tighten the coolant heater to 50 Nm (37 ft. lbs.). 2. Install the coolant heater cord to the heater (2). NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 3. Install the engine harness bracket and secure the bracket with the bolt. Tighten the engine harness bracket bolt to 45 Nm (33 ft. lbs.). 4. Secure the harnesses to the bracket. 5. Install the PCM. 6. Fill the cooling system. Page 10370 Abbreviations And Meanings Part 23 Speaker Replacement Reference Speaker Replacement Reference Page 5038 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Electronic Brake Control Module (EBCM) C1 Service and Repair Power Steering Fluid Reservoir: Service and Repair Power Steering Reservoir Replacement - Off Vehicle (CB Series) Disassembly Procedure 1. Place the hydraulic pump (1) on a fixed, flat surface, with the shaft facing upward. Page 13222 Page 12809 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 814 A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Shift Cable: All Technical Service Bulletins A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Page 7205 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 13256 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Instruments - Erratic Speedometer Operation Engine Control Module: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 11810 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 10336 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Engine Controls - SES Lamp ON/DTC's P0133/P0172 PROM - Programmable Read Only Memory: Customer Interest Engine Controls - SES Lamp ON/DTC's P0133/P0172 Bulletin No.: 04-06-04-053 Date: July 20, 2004 TECHNICAL Subject: Service Engine Soon Light On, P0133, P0172 (Reprogram PCM) Models: 2004 Buick Rainier 2003-2004 Chevrolet Trailblazer 2003-2004 GMC Envoy 2003-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon light coming on and no apparent vehicle driveability condition. Upon investigation, the technician will find diagnostic trouble codes P0133 or P0172. Correction Reprogram the PCM with the latest calibration available. The new calibration will be released beginning with TIS satellite data update version 2.5 for 2004 available February 2004. As always, make sure your TECH2(R) is updated with the latest software version. Warranty Information For vehicles repaired under the applicable 8 year or 80,000 mile (130,000 kilometers) emission controller warranty, use the table. Disclaimer Page 10304 Page 2833 Registered And Non-Registered Trademarks Part 5 Page 73 Abbreviations And Meanings Part 18 Page 842 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 11803 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 6297 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Page 2022 1. Apply coolant to the end of the heater inlet hoses. 2. Install the heater inlet hose to the inlet hose fitting at the engine block. IMPORTANT:When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 3. Install the nut retaining the coolant bypass valve to the cowl. Tighten Tighten the nut to ......10 N.m (89 lb in). 4. Install the inlet heater hose to the engine block. 5. Reposition the inlet heater hose clamp at the engine block using J 38185. 6. Install the quick connect end of the inlet heater core hose to the heater core. 7. Install the coolant recovery reservoir. 8. Fill the engine cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6) in Cooling System. Page 7159 12. Disconnect the body wiring harness connector (1) from the junction block. 13. Disconnect the headliner harness connector (2) from the junction block. 14. Disconnect the console harness connector from the junction block. 15. Remove the block base retaining nuts from the floor studs. 16. Remove the block base from the floor panel. INSTALLATION PROCEDURE 1. Install the block base to the floor studs. 2. Install the block base retaining nuts to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the block base retaining nuts to 10 N.m (88 lb in). 3. Connect the console harness connector to the block base. 4. Connect the headliner harness connector (2) to the block base. 5. Connect the body wiring harness connector (1) to the block base. Page 4980 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector.Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON transmission fluid. Page 10315 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 830 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Lighting - Tail Lamp(s) Inoperative Tail Lamp Socket: Customer Interest Lighting - Tail Lamp(s) Inoperative Bulletin No.: 03-08-42-006B Date: May 26, 2004 INFORMATION Subject: Tail Lamp Circuit Board Now Available For Service Use Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add a part number. Please discard Corporate Bulletin Number 03-08-42-006A (Section 08 - Body and Accessories). A new tail lamp circuit board is now available for service use. If normal diagnosis of a vehicle leads to a failed tail lamp bulb, inspect the bulb socket to ensure proper fit of the bulb into the socket. If the bulb is found to be loose, or if the circuit board has failed, replace both tail lamp circuit boards with the new part number from GMSPO. Technicians are to replace the tail lamp circuit boards, on both sides of the vehicle, using the following procedure: 1. Remove the tail lamp assembly from the vehicle. 2. Remove the tail lamp circuit board from the tail lamp assembly. 3. Inspect for loose tail lamp bulbs in the tail lamp circuit board. Replace the tail lamp bulb and the tail lamp circuit board if necessary. 4. Install the tail lamp circuit board. 5. Install the tail lamp assembly. 6. Replace the tail lamp circuit board on the opposite side of the vehicle using the above procedure. 7. Verify the operation of the tail lamps. Parts Information OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 6610 started. Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE 1. Insert a small coin between the two halves of the transmitter case at the slot provided near the key ring hole. 2. Twist the coin in order to open the case. 3. Open the transmitter case. 4. Remove the battery. NOTE: Refer to Handling ESD Sensitive Parts Notice in Service Precautions. INSTALLATION PROCEDURE 1. Install the battery with the positive (+) side down. Use one 3 volt, type CR2032 battery, or the equivalent. 2. Ensure that the seal is in position. 3. Align the two halves of the case together and squeeze the case closed until the tabs are fully seated. Page 12585 4. Remove the retainer nut (2) from each end of the seat latch rod (1). 5. Remove the seat latch rod. INSTALLATION PROCEDURE 1. Install the seat latch rod (1) to the inner and outer riser assemblies. 2. Install a retainer nut (2) on each end of the seat latch rod (1). 3. Install the seat riser latch assembly (1) to the seat latch rod (2). 4. Install the rear seat cushion assembly (1) to the seat latch rod (3) with two bolts (2). Page 4457 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 4764 Resonator: Service and Repair Air Cleaner Resonator Outlet Duct Replacement REMOVAL PROCEDURE 1. Remove the air cleaner element. 2. Disconnect the electrical connector from the intake air temperature (IAT) sensor (1). 3. Loosen the air cleaner outlet duct clamp (2) on the air cleaner side of the air cleaner outlet resonator (3). 4. Remove the air cleaner outlet duct. 5. If replacing the air cleaner outlet duct, remove the IAT sensor. INSTALLATION PROCEDURE 1. If the IAT sensor was previously removed, install the IAT sensor into the air cleaner outlet duct. 2. Install the air cleaner outlet duct onto the air cleaner outlet resonator (3). 3. Install the air cleaner element. 4. Properly position the air cleaner outlet duct clamp (2) on the air cleaner side of the air cleaner outlet resonator (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the clamp (2) to 4 N.m (35 lb in). 5. Connect the electrical connector to the IAT sensor (1). Page 11816 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 4047 Powertrain Control Module (PCM) C3 Part 3 Page 3262 Do NOT replace an EV fan unless a specific condition related to the EV fan is identified using SI diagnostics. If the fan has a condition that warrants replacement, a DTC should set and/or SI diagnostics should lead to the replacement of the fan clutch. If the fan is not operating at the proper speed/function, the appropriate diagnostic trouble code should set. Identify the root cause of the condition. Please make sure to do a thorough review of SI for proper diagnostics. Several Service Bulletins and Preliminary Information are available on SI regarding the EV fan. Refer to "Operating Characteristics" and "Diagnostic Tips" in this bulletin for additional information. Operating Characteristics of the Electro-Viscous (EV) Fan Clutch Changes to the EV fan clutch to improve the HVAC performance basically increase airflow in certain conditions. It is now possible during start up for the EV fan clutch to be engaged and match engine speed for about 1 minute depending on driving speeds (with lower speeds having a longer disengagement time) producing some noise/flare. The noise/flare will most likely be intermittent and can be dependent on the following conditions: ^ Fan clutch valve orientation, with check ball at 11:00 position as viewed from front of vehicle when the engine is stopped. ^ HVAC or powertrain cooling conditions when the vehicle is shut off. ^ Parking incline - vehicles parked nose up on a 16% or higher incline (such as vehicles coming off transport or parked on steep driveways) may have prolonged fan noise/flare until the fluid is pumped out of the working chamber of the fan. These conditions can occur in as little as ten minutes. Once the vehicle is not parked in these conditions, it should operate as expected. ^ Please note that if the vehicle is parked nose down with a 16% or more decline, the EV fan clutch may have a delayed engagement response similar to what is described in Corporate Bulletin Number 04-01-38-019A. Important: Do not replace EV fan clutches for these conditions listed above; they are expected vehicle characteristics. If the fan clutch is truly operating at a speed higher than intended, a DTC P0495 or P1484 should set. Additional codes are available for other conditions. Diagnostic Tips Depending on the vehicle year, the Tech 2(R) may allow some EV fan control using the special functions application of the Tech 2 (refer to the proper SI documentation). If this function or a fused jumper wire is being used to check EV fan response, there may be a delay in fan response (up to 2-3 minutes depending on conditions, please refer to SI diagnostics). The desired fan speed and actual fan speed data (on the Tech 2(R)) can be misleading. The desired fan speed is comprised of the maximum of multiple parameters (for example engine coolant temp, A/C pressure, etc.) and may not be the ruling desired fan speed parameter. The end result may be that the actual desired fan speed is lower than what is displayed. Additionally, the desired fan speed may be higher than the current engine speed. The fan is limited by the current engine RPM and will max out at about 3500 RPM under full manual fan engagement request along with a corresponding engine RPM speed. The 4.2L 1-6 (LL8) engine's desired and actual fan speeds will usually be closer to each other than the 5.3L V-8 (LM4 or LH6) or the 6.0L V-8 (LS2). Disclaimer Page 1113 Seat Lumbar Motors And Position Sensors Assembly - Driver Part 1 Page 6641 A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Page 9502 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 9362 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 12988 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 885 Registered And Non-Registered Trademarks Part 4 Page 11909 3. Remove the C clip from the groove in the lock cylinder. 4. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the C clip to the groove in the lock cylinder. 3. Install the lock rod to the lock cylinder. 4. Install the rear wiper motor. Refer to Wiper Motor Replacement - Rear. Page 9135 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 12525 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 12859 - Reduced Engine Power The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration. - Trans Hot Idle Engine The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration (continuous) - Turn Signal On The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration (1 pulse). Refer to Indicator/Warning Message Description and Operation. Page 4284 Abbreviations And Meanings Part 18 Page 11725 6. Remove the right rear door sill panel. 7. Remove the lower seat belt anchor bolt. 8. Release the five screws that retain the rear quarter trim panel to the body. 9. Remove the rear quarter trim panel from the vehicle. Installation Procedure 1. Position the trim panel to the vehicle. 2. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 3. Index the locating tabs on the trim panel to the holes in the body. 4. Connect the wiring harness connector to the auxiliary power outlet. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the five screws that the retain the rear quarter trim panel to the body. Tighten the rear quarter trim panel screws to 2.5 N.m (22 lb in). 6. Install the seat belt lower anchor. Tighten the seat belt anchor bolt to 70 N.m (52 lb ft). 7. Install the right rear door sill panel. 8. Install the liftgate sill plate. 9. Install the right body side window forward garnish molding. 10. Install the right body side window rear garnish molding. 11. Return the third row seats to the upright position. 12. Install the cargo shelf. Trim Panel Replacement - Rear Quarter - Right (TrailBlazer, Envoy, Bravada) Trim Panel Replacement - Rear Quarter - Right (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the cargo shade/cover. A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Page 6752 Page 13189 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module yellow 4-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 1. Remove the key from the ignition. Page 5937 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Brake Caliper Bracket Replacement Brake Caliper: Service and Repair Brake Caliper Bracket Replacement Front Brake Caliper Bracket Replacement - Front Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Inspect the brake caliper assembly. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 4. Remove the front brake caliper assembly, relocate the brake caliper to the side. 5. Inspect the brake pads. 6. Remove the front brake pads from the mounting bracket, inboard brake pad shown. 7. Inspect the brake hardware. Page 538 Front Passenger Door Module (FPDM) Page 13993 * The defogger terminal Important: Do not remove the holding force until the solder has solidified. 14. Remove the excess flux with the solvent. 15. Connect the electrical connector. Page 12905 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 7600 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Page 6352 Brake Caliper: Service and Repair Brake Caliper Replacement Front Brake Caliper Replacement- Front Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the front brake hose bolt. 4. Install a plug in the front brake caliper hose in order to prevent excessive brake fluid loss and contamination. 5. Discard the metal/copper gaskets. DO NOT reuse them replace with NEW metal/copper gaskets. 6. Remove the front brake caliper mounting bolts. 7. Remove the front brake caliper from the mounting bracket. Installation Procedure Page 7559 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 754 1. Connect the HVAC control-auxiliary electrical connector. 2. Install the HVAC control-auxiliary in the console bottom first. 3. Push in at the top of the HVAC control-auxiliary in order to engage the HVAC control-auxiliary in the console/seat. Page 6685 Abbreviations And Meanings Part 7 Page 2581 Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt First Pass 110 ft. lbs. Final Pass 180 degrees Page 12104 Door Module: Locations Door Lock Switch, Window Switch, Driver Door Module (DDM) Navigation Control Processor Bracket Replacement 1 Navigation System: Service and Repair Navigation Control Processor Bracket Replacement 1 NAVIGATION CONTROL PROCESSOR BRACKET REPLACEMENT (TRAILBLAZER, ENVOY, BRAVADA) REMOVAL PROCEDURE 1. Remove the right rear seat cushion. 2. Remove the communication interface module. 3. Using a flat bladed tool, release the retaining tab on the upper bracket. 4. Slide the upper bracket inboard until the retaining tabs are released from the processor bracket. 5. Remove the upper bracket from the processor bracket. 6. Remove the nut that retains the processor bracket to the rear seat back stud. 7. Remove the processor bracket from the vehicle. INSTALLATION PROCEDURE Page 11160 Page 587 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 2504 4. Install the J-44217 (1). 4.1 Install the hook portion of the timing chain retention tools into one of the timing chain links near the timing chain shoe on both sides of the engine. 4.2 Tighten the wingnuts. 4.3 Ensure the hooks are still in one of the links and the gauge blocks of the tool are firmly in place on the edge of the head. 5. Remove the exhaust camshaft position actuator bolt. 6. Remove the exhaust camshaft position actuator. Installation Procedure A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 2398 Disclaimer Page 4157 Information Bus: Symptom Related Diagnostic Procedures A Symptoms - Data Link Communications SYMPTOMS - DATA LINK COMMUNICATIONS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the applicable diagnostic system check before using the Symptom Tables in order to verify that there are no DTCs set. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the vehicle systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Scan Tool Does Not Power Up - Scan Tool Does Not Communicate with Class 2 Device (W/O Immobilizer) Scan Tool Does Not Communicate with Class 2 Device (W/ Immobilizer) With Immobilizer SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE (W/ IMMOBILIZER) CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the DLC allows communication with the modules for diagnostic purposes. DTCs may be set due to this symptom and during this diagnostic procedure. Complete the diagnostic procedure in order to ensure all the DTCs are diagnosed and cleared from memory. DIAGNOSTIC AIDS - The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must be connected to the DLC for any other module to communicate with the scan tool. - When the class 2 serial data circuit: is shorted to ground - is shorted to voltage The following DTCs may set: U1300 - U1301 - U1305 TEST DESCRIPTION Page 6909 Abbreviations And Meanings Part 24 Page 2892 Page 11683 Scuff Plate: Service and Repair Door Sill Plate Replacement - Rear (TrailBlazer, Envoy, Bravada) Door Sill Plate Replacement - Rear (TrailBlazer, Envoy, Bravada) Removal Procedure 1. Use a flat-bladed tool in order to release the 3 sill plate retaining tabs. 2. Remove the sill plate from the door frame. 3. Remove any retaining tabs that remain attached to the door frame. Installation Procedure 1. Ensure that all 3 retaining tabs are attached to the sill plate. 2. Align the retaining tabs to the door frame slots. 3. Push down on the sill plate, seating the retaining tabs to the door frame. Control Module HVAC Control Module HVAC: Service and Repair Control Module HVAC HVAC Control Module Replacement Removal Procedure 1. Remove the I/P accessory trim plate. 2. Remove the HVAC control module screws. 3. Depress the HVAC control module tabs (3) and remove the HVAC control module (2) from the I/P (4). 4. Disconnect the electrical connectors (1) from the HVAC control module (2). Installation Procedure 1. Connect the electrical connectors (1) to the HVAC control module (2). Important: Ensure that the HVAC control module tabs (3) lock into place. 2. Install the HVAC control module (2) into the I/P (4). Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the HVAC control module screws. Tighten the screws to 1.9 Nm (17 in. lbs.). 4. Install the I/P accessory trim plate. Page 10123 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 10436 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 12842 Abbreviations And Meanings Part 19 Page 6488 6. Install a pole jack with a block of wood under the fuel tank. 7. Remove the shield for the fuel tank. 8. Remove the rear support bracket from the fuel tank. Important: When performing this service procedure, the fuel tank will only drop about four inches when supported by the pole jack. It is not necessary to lower the fuel tank any further than that. 9. Lower the fuel tank to allow access to the rear park brake cable retainer above the fuel tank. 10. Remove the park brake cable retaining nuts from the underbody mounting studs. 11. Remove the park brake cable from the park brake cable retainers, left rear shown. Page 12461 3. Install the cover flaps to the pad with hog rings (1). 4. Install the seat cushion panel on the pad and cover. 5. Install the J-strips (2) securing the seat cushion cover to the seat cushion panel. 6. Install the pull handle assembly (1). 7. Install the rear seat cushion assembly (1) to the seat latch rod (3) with two bolts (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat cushion bolts to 11 N.m (97 lb in). Locations Electronic Components Page 12145 Various symbols in order to describe different service operations. Locations Blower Motor Switch: Locations Front Auxiliary Blower Motor Switch (w/Manual HVAC System / Body Type VIN 6) Page 6715 6. Remove the 3 generator mounting bolts and remove the generator. INSTALLATION PROCEDURE 1. Install the generator and secure the generator with 3 bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the generator bolts to 50 N.m (37 lb ft). 2. Connect the battery positive cable to the generator and secure the positive cable with the nut (1). Tighten Tighten the generator positive cable nut to 9 N.m (80 lb in). Page 7463 C105 Part 2 Page 3580 Engine Control Module: Diagrams Powertrain Control Module (PCM) C2 Powertrain Control Module (PCM) C2 Part 1 Page 1750 Abbreviations And Meanings Part 14 Page 2793 Conversion - English/Metric Part 1 Page 9281 Antenna Cable: Service and Repair Antenna Cable Replacement ANTENNA CABLE REPLACEMENT REMOVAL PROCEDURE 1. Open the instrument panel (I/P) compartment to a full down position. 2. Disconnect the radio antenna cable (2) from the radio extension cable. 3. Remove the lower rear portion of the wheelhouse panel. 4. Reach up behind the wheelhouse panel and remove the antenna cable and grommet assembly from the cowl opening (1). 5. Pass the end of the radio antenna cable assembly through the cowl opening (1). 6. Remove the antenna mast. 7. Open the hood. Page 2156 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ......................................................................................................................................... Polyalkaline Glycol (PAG) Refrigerant Oil Page 10380 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 2836 Oil Pressure Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Page 12064 WA805K/62 - WA810K/48 Page 2217 Fuse Block - Rear C2 Part 2 Page 9327 Page 823 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 11158 9.1. Replace the latch assembly. 9.2. Proceed to Step 11. 10. If two distinct audible clicks are heard: 10.1. Ensure that the fork bolt is in the fully latched position. 10.2. Blow out the latch in the area of the detent with compressed air. 11. Lubricate both sides of the detent pivot by spraying with GM Superlube for one second, and then cycle the latch open and closed several times to work the lubrication into the pivot. 12. Repeat Steps 1 through 11 for the rear door on the other side. Page 2487 Variable Valve Timing Solenoid: Service and Repair CAMSHAFT POSITION (CMP) ACTUATOR SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the drive belt. 2. Remove the 3 power steering pump bolts and move the pump out of the way. 3. Disconnect the camshaft position actuator solenoid electrical connector. 4. Remove the camshaft position actuator solenoid retaining bolt (3). 5. Remove the camshaft position actuator solenoid (2) from the engine block. 6. Clean debris from the hole (1). INSTALLATION PROCEDURE 1. Install a new O-ring on the camshaft position actuator solenoid. 2. Lubricate the hole (1) with engine oil. 3. Install the camshaft position actuator solenoid (2) and bolt (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Connect the camshaft position actuator solenoid electrical connector. 5. Install the power steering pump and bolts. 6. Install the drive belt. Page 12802 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 11476 sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 14018 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 1404 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the fuel tank pressure harness connector. 3. Remove the fuel tank pressure sensor. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor seal. 2. Install the fuel tank pressure sensor. 3. Connect the fuel tank sensor harness connector. 4. Lower the vehicle. Page 789 Application Table Part 4 Location View Page 4499 EVAP Vent Valve 1. Install the EVAP canister vent valve (1) on the bracket (2). 2. Inspect for proper retention of the EVAP vent valve (1) on the bracket (2). 3. Connect the EVAP vent pipe (3) to the EVAP canister vent valve (1). 4. Connect the harness connector (2) to the EVAP canister vent valve. 5. Lower the vehicle. Page 13536 Miniwedge (Door Jamb Switch) - RR Page 3240 For vehicles repaired under warranty, use the table. Disclaimer Page 12897 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. A/C - Musty Odors On Start Up Evaporator Core: All Technical Service Bulletins A/C - Musty Odors On Start Up Bulletin No.: 05-01-39-002A Date: March 17, 2006 TECHNICAL Subject: Musty Odor from HVAC System (Reprogram HVAC Control Module to Enable Afterblow Function) Models: 2004-2006 Buick Rainier 2003-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2003-2004 Oldsmobile Bravada with Automatic Temperature Control HVAC System (RPO CJ2) Supercede: This bulletin is being revised to add the 2006 model year and update the calibration release date. Please discard Corporate Bulletin Number 05-01-39-002 (Section 01 - HVAC). Condition Some customers may comment on a musty odor from the Heating, Ventilation and Air Conditioning (HVAC) system. This condition occurs most often on initial start up after the vehicle was driven on a hot humid day. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. Correction Important: The afterblow function should not be enabled until after the purpose and operation of it is explained to your customer and they approve of the change. Once the afterblow function is enabled there are no calibrations currently released to disable it. Technicians are to reprogram the HVAC Control Module with an updated software calibration that will enable the afterblow function. The new calibration will be released beginning with TIS satellite data update version 2.0, which was made available February 5, 2006. The blower motor will turn on approximately 10 minutes after the vehicle is shut off. The blower motor will run continuously for 10 minutes at a 30% duty cycle. The afterblow function will only activate if the air conditioning compressor was engaged during conditions of high ambient temperature. If the vehicle is started within 10 minutes of the last key off, the afterblow function from the previous key cycle will be cancelled. Technicians should not attempt to reprogram a vehicle with a Manual Temperature Control HVAC system (RPO CJ3). Technicians should perform this HVAC Control Module reprogram instead of installing the Electronic Evaporator Dryer Module Kit referred to in the Air Conditioning Odor bulletin, Corporate Bulletin Number 99-01-39-004A. Warranty Information Page 1096 Power Door Lock Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the rear door ajar switches in the door lock assemblies as one method to activate the alarm. The body control module (BCM) monitors rear door ajar switches via a discrete input from each rear passenger door ajar switch, if the BCM receives a ground signal from a rear passenger door ajar switch when the CTD system is armed, the BCM activates the alarm. The CTD system uses the LH front door ajar switch as one method to activate the alarm. The driver door module (DDM) monitors the LH door ajar switch via a discreet input from the door ajar switch, if the DDM receives a ground signal from the LH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the RH front door ajar switch as one method to activate the alarm. The passenger door module (PDM) monitors the RH door ajar switch via a discreet input from the door ajar switch, if the PDM receives a ground signal from the RH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the rear compartment liftgate/liftglass ajar switchs as one method to activate the alarm. The liftgate module (LGM) monitors the liftgate and liftglass ajar switch via a discreet input from the ajar switch, if the LGM receives a ground signal from the liftgate or liftglass ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. Page 4222 Page 2988 Installation Procedure 1. Install the engine oil level sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine oil level sensor mounting bolt. ^ Tighten the engine oil level sensor mounting bolt to 10 Nm (89 inch lbs.). 3. Connect the electrical connector to the engine oil level sensor. 4. Install the engine protection shield. 5. Install the engine protection shield mounting bolts. ^ Tighten the engine protection shield mounting bolts to 25 Nm (18 ft. lbs.). Page 1240 Front Auxiliary Blower Motor Switch (w/Automatic HVAC System / Body Type VIN 6) Page 10008 Page 2165 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 2901 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 9141 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 13270 Abbreviations And Meanings Part 8 Page 9172 Abbreviations And Meanings Part 5 Page 3871 Page 12505 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Battery Negative Cable Disconnect/Connect Procedure Negative: Service and Repair Battery Negative Cable Disconnect/Connect Procedure DISCONNECTING PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Record all preset and theft codes from the radio. 2. Turn the ignition switch to the LOCK position. 3. Verify that all the electrical components are off such as interior lights, all doors are closed, the underhood lamp, etc. 4. Loosen the negative battery cable bolt. 5. Remove the negative battery cable (4) from the battery. 6. Position the negative battery cable away from any body ground. CONNECTING PROCEDURE 1. Verify that all electrical components are off such as interior lights, all doors are closed, the underhood lamp, etc. 2. Clean any corrosion from the negative battery cable using a wire brush. 3. Position the negative battery cable (4) to the battery. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten negative battery cable bolt. Tighten Tighten the bolt to 15 N.m (11 lb ft). Page 11899 Power Door Lock Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the rear door ajar switches in the door lock assemblies as one method to activate the alarm. The body control module (BCM) monitors rear door ajar switches via a discrete input from each rear passenger door ajar switch, if the BCM receives a ground signal from a rear passenger door ajar switch when the CTD system is armed, the BCM activates the alarm. The CTD system uses the LH front door ajar switch as one method to activate the alarm. The driver door module (DDM) monitors the LH door ajar switch via a discreet input from the door ajar switch, if the DDM receives a ground signal from the LH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the RH front door ajar switch as one method to activate the alarm. The passenger door module (PDM) monitors the RH door ajar switch via a discreet input from the door ajar switch, if the PDM receives a ground signal from the RH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the rear compartment liftgate/liftglass ajar switchs as one method to activate the alarm. The liftgate module (LGM) monitors the liftgate and liftglass ajar switch via a discreet input from the ajar switch, if the LGM receives a ground signal from the liftgate or liftglass ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. Page 9725 Television / Monitor: Service and Repair VIDEO DISPLAY REPLACEMENT REMOVAL PROCEDURE 1. Turn the ignition switch to the OFF position. IMPORTANT: Do not attempt to service the video display assembly components. The video display is serviced only as an assembly. 2. Using a plastic flat bladed tool, carefully remove the bolt cover bezel. 3. Fully loosen the two rear retaining bolts. The bolts will remain attached to the video assembly. 4. In order to expose the two front retaining bolts, adjust the video display screen to a full open position. 5. Fully loosen the front retaining bolts. The bolts will remain attached to the video assembly. 6. Close the video display screen. 7. Slowly lower the front of the video assembly to release the retaining fastener (3). 8. Support the video assembly and disconnect the electrical connector (2). 9. Adjust the video assembly in order to release the T-hook (1) from the video player bracket. 10. Remove the video assembly from the vehicle. INSTALLATION PROCEDURE Page 12165 Abbreviations And Meanings Part 10 Page 6224 Abbreviations And Meanings Part 23 Page 8990 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 8. CAUTION: Refer to SIR Caution in Service Precautions. 2. Remove the floor console. 3. Partially remove the console mounting bracket in order to allow access to the rear carpet. Refer to Bracket Replacement - Console Floor in Instrument Panel, Gages, and Console. 4. Position the rear carpet in order to access the sensing and diagnostic module (SDM). 5. Disconnect the electrical connectors (2) from the SDM (1). 6. Remove the nuts that retain the SDM to the floor panel. 7. Remove the SDM from the vehicle. Installation Procedure Page 6779 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 13709 Turn Signal/Multifunction Swtich C4 Page 10433 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 2301 Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Page 13254 Conversion - English/Metric Part 2 Page 12431 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Page 2787 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 10335 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 911 2. Connect the 24-way gray electrical connector (1) to the BCM. 3. Connect the 32-way tan electrical connector (2) to the BCM. 4. Connect the body wiring extension (1) to the BCM. 5. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. Page 14008 Page 8339 Page 6164 Recall 03V151000: Front Brake Pipe Replacement Brake Hose/Line: Recalls Recall 03V151000: Front Brake Pipe Replacement DEFECT: Certain sport utility vehicles were built with a left-front brake pipe with a circumferential score at a random location along the length of the pipe as the result of the manufacturing process. If the brake pipe partially or fully fractured, brake pedal travel would immediately increase and front brake performance would be reduced, a crash could occur. REMEDY: Dealers will replace the left-front brake pipe. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners may contact Chevrolet at 1-800-222-1020, GMC at 1-800-462-8782, or Oldsmobile at 1-800-442-6537. Page 2679 3. Install the left engine mount bracket and secure the bracket with the bolts (1). Tighten the engine mount bracket bolts to 50 Nm (37 ft. lbs.). 4. Install the left engine mount onto the bracket. 5. Lower the engine onto the engine mounts. 6. Install the right and the left upper engine mount nuts. Tighten the upper engine mount nuts to 70 Nm (52 ft. lbs.). 7. Raise the vehicle and remove the jack from under the vehicle. Page 10131 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. M/T - Hydraulic Clutch Bleeding Procedure Improvement Clutch Hydraulic System: Technical Service Bulletins M/T - Hydraulic Clutch Bleeding Procedure Improvement Bulletin No.: 01-07-31-002B Date: November 01, 2006 INFORMATION Subject: Improved Bleeding Procedure for Hydraulic Clutch Release System Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2007 and Prior Chevrolet and GMC 6-7F T-Series Medium Duty Tilt Cab Models 2007 and Prior Isuzu F-Series Medium Duty Tilt Cab Models 2006-2007 HUMMER H3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-07-31-002A (Section 07 - Transmission/Transaxle). This bulletin is being issued to inform dealers of an improved procedure to aid in the ease of bleeding the clutch hydraulic system for the above listed vehicles. This procedure can be used anytime air is introduced into the hydraulic system. Following this procedure may also reduce the number of unnecessary parts replaced for low clutch pedal reserve and high shift effort. Verify that all the lines and fittings are dry and secure. Clean the dirt and grease from the reservoir cap in order to ensure that no foreign substances enter the system. Remove the reservoir cap. Fill the reservoir to the proper level with the required fluid. Attach the J 43485 (Adapter) to the J 35555 (Mity Vac), or equivalent. Brake fluid will deteriorate the rubber on J 43485. Use a clean shop cloth to wipe away the fluid after each use. Place and hold the adapter on the reservoir filler neck to ensure a tight fit. In some cases, the adapter will fit into the reservoir opening. Apply a vacuum of 51-68 kPa (15-20 hg) and remove the adapter. Refill the reservoir to the proper level. Repeat Steps 6 and 7. If needed, refill the reservoir and continue to pull a vacuum until no more bubbles can be seen in the reservoir or until the fluid level no longer drops. The vehicle will move if started in gear before the Actuator Cylinder is refilled and operational. Start the vehicle the first time in neutral to help prevent personal injury from vehicle movement and see if the transmission will shift easily into gear. Pump the clutch pedal until firm (to refill actuator cylinder). Add additional fluid if needed. Test drive vehicle to ensure proper operation. Disclaimer Page 12502 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 10133 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 2444 Disclaimer Page 9830 Abbreviations And Meanings Part 22 Page 11370 Disclaimer Page 10620 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 12624 Lumbar Adjuster Switch - Passenger (w/o Heat) Page 4918 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 12901 Various symbols in order to describe different service operations. Page 1505 32. Install the new hose (1), # 1005 (L6 engine) or# 1006 (V8 engine) onto the coolant bypass valve at the location the above hose was removed. The other end of this hose will be installed on the auxiliary heater pump outlet port. Page 659 Memory Seat Module - Driver C2 Part 2 Locations Blower Motor Switch: Locations Front Auxiliary Blower Motor Switch (w/Manual HVAC System / Body Type VIN 6) Page 10164 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Page 2826 Abbreviations And Meanings Part 24 Page 12874 Page 11349 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 screws (2) that retain the lock actuator (1) to the latch assembly. Tighten the screws to 0.75 N.m (6 lb in). 5. Install the latch assembly to the liftgate. Page 6243 Brake Caliper: Technical Service Bulletins Brakes - Rear Caliper Mounting Bolt Torque Revision Bulletin No.: 04-05-23-003 Date: April 22, 2004 SERVICE MANUAL UPDATE Subject: Revised Rear Brake Caliper Bracket Mounting Bolt Fastener Specification Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2004 Isuzu Ascender This bulletin is being issued to revise the fastener tightening specification for the rear brake caliper bracket mounting bolt in the Disc Brakes sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The revised specification is as follows: Rear Brake Caliper Bracket Mounting Bolt - 200 N.m (147 lb ft) Disclaimer Page 11416 Quarterglass Actuator - R Air Suspension Sensor - LR Page 2223 Fuse Block - Rear C3 Part 2 Page 7315 Application Table Part 1 Page 13130 Abbreviations And Meanings Part 2 Page 4274 Abbreviations And Meanings Part 8 Page 7689 6. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 7. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 8. Disconnect the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 9. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 10. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Page 9397 Registered And Non-Registered Trademarks Part 5 Page 9179 Abbreviations And Meanings Part 12 Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Removal Procedure 1. Open the liftgate. 2. Pull the liftgate weatherstrip from the liftgate opening pinch-weld flange. Installation Procedure 1. Install the liftgate weatherstrip, starting at the top center of the liftgate opening position the liftgate weatherstrip to the pinch-weld flange and working down the right and left sides towards the bottom center, being careful not to stretch the liftgate weatherstrip while installing it. 2. Install the butt joint seam at the center of the bottom pinch-weld flange. 3. Use a rubber mallet to ensure full engagement of the liftgate weatherstrip to the pinch-weld flange. 4. Spooning of the liftgate weatherstrip may be required to complete the installation of the liftgate weatherstrip. 5. Close the liftgate. Specifications Oil Pressure Sensor: Specifications Oil Pressure Sensor 15 ft. lbs. Page 4368 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. - Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. Removal Procedure 1. Loosen the PCM harness connector bolts (1) from the center of the PCM harness connectors. 2. Remove the PCM harness connectors (3) from the PCM (2). NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 3. Remove the PCM mounting nuts and bolts (4). 4. Remove the PCM (2) from the intake manifold. NOTE: Refer to PCM and ESD Notice in Service Precautions. 5. Remove the PCM mounting studs from the intake manifold, if necessary. Installation Procedure Page 80 Abbreviations And Meanings Part 25 Page 11082 For 2007 vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 03-08-64-006C Date: 070329 Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: Customer Interest Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 12571 Seat Heater: Description and Operation HEATED SEATS DESCRIPTION AND OPERATION HEATED SEATS SYSTEM COMPONENTS The heated seats system for the driver and passenger seat consists of the following components: Driver and passenger door modules - Driver and passenger heated seat switches - Driver and passenger seat back heater elements - Driver and passenger seat back heat sensors - Driver and passenger seat cushion heater elements - Driver seat module - Passenger seat module HEATED SEATS SYSTEM OPERATION The driver and passenger heated seats have 2 heat zone operating modes with 3 heat level modes and will operate only while the engine is running. The heat zones are determined by which of the 2 heated seat buttons are pressed, while the heat level is determined by the number of times they are pressed. Pressing the seat cushion button 1 time will activate the seat back and cushion heater elements in the high mode. Each time the seat cushion button is pressed the seat back and cushion heat level is reduced from high to medium, low, and off. Pressing the heated seat back button 1 time will activate only the seat back heater element in the high mode. Each time the seat back button is pressed the seat back heat level is reduced from high to medium, low, and off. During heated seat operation the heat zone operating mode may be changed without affecting the current heat level mode. The heated seat switches are momentary contact switches and are inputs to the driver and passenger door modules. Battery voltage is supplied to the switch assembly from the door module, and when a heated seat switch is pressed and released a brief switch signal voltage is supplied to the door module. Whenever the door module receives an active heated seat switch input, the next heated seat operating mode is determined by whatever the current mode may be. The seat heater elements are controlled by the driver and passenger seat modules using inputs from the door modules through Class 2 serial data circuit messages. The seat modules control the voltage supply and the ground circuits to the seat heater elements. When a heated seat function is commanded active, the seat module will switch battery voltage to the heater element supply circuits, and ground is provided through low side drive control circuits. During heated seat operation both the seat back and cushion heater elements are supplied battery voltage. The seat module grounds the appropriate control circuits for back only or back and cushion heating modes, and opens or closes the active control circuits as necessary in order to maintain the desired seat temperature. The seat modules rely on inputs from thermistors located in the driver and passenger seat backs to control heated seat temperatures. The thermistors are 2 wire sensors supplied with a 5-voltreferenced signal circuit and a low reference circuit from the seat module. Resistance through the thermistors varies with temperature causing the heated seat sensor signal circuit voltage levels to decrease as the seat back temperatures rise. The seat modules allow heated seat operation only while the engine is running which is determined by a Class 2 serial data circuit message from the powertrain control module. Page 6019 10. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: Customer Interest Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13500 1. Install the high mount stoplamp to the lift gate window reveal molding, ensuring the center retaining tab is fully seated. 2. Install the 2 screws that retain the high mount stoplamp to the lift gate window reveal molding. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the 2 retaining screws to 2.5 N.m (22 lb in). 3. Close the liftgate window. 4. Open the liftgate. 5. Install the grommet (1) to the body. 6. Connect the high mount stoplamp electrical connector (2). 7. Attach the rear portion of the headliner to the roof panel, by seating the 2 headliner retaining pins. 8. Position the lift gate opening weatherstrip over the headliner. Page 13675 Page 6226 Abbreviations And Meanings Part 25 Page 6499 Parking Brake Lever: Service and Repair Park Brake Lever Assembly Replacement Removal Procedure 1. Remove the floor console. 2. Disable the Park Brake Automatic Adjuster. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Disconnect the park brake cables from the equalizer. 5. Lower the vehicle. 6. Disconnect the electrical connector from the park brake warning lamp switch. 7. Remove the remaining park brake lever retaining nut. 8. Remove the park brake lever assembly from the vehicle. Installation Procedure Page 13886 Page 7685 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the LF door trim panel. 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. Page 11625 1. Remove the 4 screws that retain the rear console to the roof panel. 2. Lower the rear console from the headliner. 3. Remove the rear console from the vehicle. Installation Procedure 1. Position the rear console to the roof panel ensuring the screw holes are indexed properly. 2. Partially install the 4 screws that retain the rear console to the roof panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 4 screws retaining the rear console to the roof panel. Tighten the screws to 1.2 N.m (10 lb in). Roof Console Retainer Replacement Roof Console Retainer Replacement Removal Procedure 1. Lower the headliner. Refer to Headliner Replacement (TrailBlazer, Envoy, Bravada) Headliner Replacement (TrailBlazer EXT, Envoy XL). 2. Remove the 4 screws securing the console retainer to the Z clips. 3. Remove the roof retainer from the vehicle. 4. If replacing the roof retainer, remove the Z clips from the roof panel. Installation Procedure Page 3882 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 1957 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Page 11071 Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. Page 5579 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Page 7863 1. Install the rear axle tie rod to the vehicle. 2. Install the rear axle tie rod to frame mounting bolt and nut. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear axle tie rod to the axle mounting bolt and nut. Tighten the rear axle tie rod mounting bolts to 195 Nm (144 ft. lbs.). 4. Remove the rear axle support. 5. Lower the vehicle. Page 11850 Driver Door Module (DDM) - C2 Part 1 Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 10668 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 7379 Location View Page 9783 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 7795 5. With the applicator hose down as far as possible toward the mating area of the serrations, spray a generous amount of grease. 6. Repeat the application after rotating the steering wheel 180 degrees, so that the serrations are treated in two locations opposite each other. 7. Position the floor air outlet duct into place and install the push pin retainer. 8. Raise the insulator panel and install the retaining clip to the IP substrate. 9. Install the two screws that retain the left closeout/insulator panel to the IP. Use the following steps to remove material from the upper intermediate shaft bushing. 1. Push the upper intermediate shaft boot seal (2) down toward the floor in order to completely expose the white bushing (1). 2. Using fine or very fine sandpaper, remove material from the intermediate shaft bushing. Sand around the entire face of the bushing sufficient enough to obtain clearance and reduce the drag between the intermediate shaft bushing and the upper boot seal. 3. Return the upper intermediate shaft boot seal to its original position. 4. Clean debris as necessary. Parts Information Warranty Information Page 2973 2. Use the J 44218 to install the front oil seal. 3. Remove the J44218. 4. Install the crank balancer shaft. Page 11288 Hood Latch: Adjustments Hood Latch Adjustment Inspection Procedure 1. Release the primary hood latch in order to inspect the operation of the pop-up spring. 2. Attempt to raise the hood while the hood is in the pop-up position. * The hood should raise without the hood striker binding against the latch. * The secondary latch should engage in order to prevent the hood from being raised. Adjustment Procedure 1. Loosen the bolts retaining the hood latch to the support bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Move the hood latch from side to side until the striker enters the center of the latch assembly. Tighten the bolts retaining the hood latch to the support bracket to 10 N.m (89 lb in). Page 8608 1. Install the expansion tube (4) to the evaporator tube (1). IMPORTANT:Install the shorter screen end of the expansion tube into the evaporator tube first. 2. Use the J 26549-E in order to install the expansion tube (4). 3. Install the new O-ring seal. 4. Assemble the evaporator tube at the block fitting (3). 5. Install the nut (2) to the evaporator tube block (3).Install the evaporator tube nut. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the nut to .....28 N.m (21 lb ft). 6. Install the evaporator tube to the evaporator. 7. Install the evaporator tube nut (5) to the evaporator. Tighten Tighten the nut to .....28 N.m (21 lb ft). 8. Install the coolant reservoir. 9. Install the accumulator. 10. Recharge the refrigerant system. 11. Leak test the fittings of the components using the J 39400. Page 897 Body Control Module (BCM) C3 Part 4 Page 211 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 5032 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3664 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield. 3. Remove the electrical connector from the oil pressure switch. 4. Remove the oil pressure switch. Installation Procedure NOTICE: Refer to Fastener Notice in Service Precautions. See: Engine, Cooling and Exhaust/Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the oil pressure switch. Tighten the oil pressure switch to 20 Nm (15 ft. lbs.). 2. Install the electrical connector to the oil pressure switch. 3. Install the engine shield. 4. Lower the vehicle. Page 13924 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 7449 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 2589 Piston: Specifications Piston Diameter - (1.4961 inch) down from top 3.6627-3.6633 inch Piston to Bore Clearance 0.0004-0.0017 inch Piston to Pin Clearance 0.00012-0.0005 inch Pin Bore 0.9056-0.9058 inch Piston Pin Diameter 0.9054-0.9055 inch Locations Door Lock Switch, Window Switch, Driver Door Module (DDM) Page 1768 Registered And Non-Registered Trademarks Part 6 Page 8009 Vehicle Lifting Points The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: - Beneath the lower control arms, inboard from the shock absorber mounts - Beneath the center of the front crossmember Page 12562 Registered And Non-Registered Trademarks Part 4 Page 60 Abbreviations And Meanings Part 5 Page 1764 Registered And Non-Registered Trademarks Part 2 Page 7692 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the EFS connectors to both (2) EFS's. 3. Install the CPAs to both EFS connectors. 4. Install sensor bracket to bumper. 5. Install the grille. 6. Install the SIR fuse into the fuse block (1) located in the underhood fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 1. Remove the key from the ignition. Page 12192 Mirror Connector, Driver Door Module (DDM) - C3 Part 1 Page 7346 Fuse Block - Underhood C1 Part 3 Page 7329 Fuse Block - Rear C1 Part 3 Steering - Steering Column Squeaking/Rubbing Noise Steering Shaft Coupler: Customer Interest Steering - Steering Column Squeaking/Rubbing Noise Bulletin No.: 02-02-35-006B Date: March 17, 2006 TECHNICAL Subject: Squeak, Rub/Scrub Type Noise in Steering Column (Lubricate Upper Intermediate Shaft Serration (Slip) Joint and Remove Material from Upper Intermediate Shaft Bushing) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to change the lubricant part number. Please discard Corporate Bulletin Number 02-02-35-006A (Section 02 - Steering). Condition Some customers may comment on a squeak noise coming from the steering column while turning the steering wheel. Some customers may also comment on a rubbing/scrubbing type noise/feel in the steering wheel during low speed turns/parking maneuvers. This condition may be more pronounced in cold temperatures. The rubbing/scrubbing noise condition affects vehicles built prior to VIN breakpoint 32214010 (Moraine, OH) and 36170447 (Oklahoma City, OK). Cause Inadequate distribution and amount of grease in the serration (slip) joint of the upper intermediate shaft may cause the squeak noise. The rubbing/scrubbing type noise may be due to an interference fit between the upper intermediate shaft boot seal and the intermediate shaft bushing. Correction Lubricate the upper intermediate shaft serration (slip) joint. After lubrication, remove material from the upper intermediate shaft bushing. Use the following procedure. 1. Remove the two screws that retain the left closeout/insulator panel to the instrument panel (IP). 2. Release the insulator panel retaining clip from the IP substrate and lower the panel. 3. Remove the push pin retainer and the LH floor air outlet duct from the heater module. 4. Insert the flexible applicator hose of the spray lubricant, P/N 89021668 (Canadian P/N 89021674), through the top, hollow end (1) of the intermediate shaft. Page 9060 2. Install the inboard rear seat back cushion latch cover with 3 screws. Tighten Tighten the rear seat back cushion latch cover screws to 2 N.m (18 lb in). Page 1227 Ambient Air Temperature Sensor Page 10561 Parts Information Page 11478 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the windshield wiper arms. 2. Remove the inlet grille panel retaining nuts and push-pin retainers. 3. Remove the inlet grill panel pushpin retainers. 4. Disconnect the washer hose connection. 5. Remove the inlet grille panel from the vehicle, by pulling upwards in order to disengage the retaining clips. 6. Place the inlet grille panel on a clean, prepared surface. 7. Remove the rear hood seal from the inlet grille panel studs. 8. Remove the rear hood seal from the inlet grille panel. Installation Procedure 1. Position the rear hood seal to the inlet grille panel. 2. Install the rear hood seal to the inlet grille panel studs. 3. Position the inlet grille panel to the vehicle. 4. Press the inlet grille panel downward in order to seat the retaining clips. 5. Push downward on the inlet grille panel to seat the retaining clips. 6. Connect the washer hose connection. 7. install the pushpin retainers. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the inlet grille retaining nuts and push-pin retainers. Tighten the air inlet grille nuts to 4 N.m (35 lb in). 9. Install the windshield wiper arms. Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 2961 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Capacity Specifications Refrigerant Oil: Capacity Specifications Page 2604 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the fuel pressure service connection cap. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Install the fuel tank shield if removed. Page 839 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 2288 9. Install the 3 bolts (1) that retain the junction block to the block base. Tighten Tighten the 3 bolts to 3.5 N.m (31 lb in). 10. Install the BCM to the rear electrical center. 11. Install the battery feed terminal nut (2) to the junction block. Tighten Tighten the battery feed terminal nut to 10 N.m (88 lb in). 12. Install the rear electrical center cover. 13. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a passenger position. 14. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 15. Connect the battery negative cable. Page 7495 C315 Part 2 Page 11611 11. Remove the bocks from the vehicle. Page 12969 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 2144 Disclaimer Page 6026 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 8271 7. Install the left closeout/insulator panel. Page 12535 Abbreviations And Meanings Part 3 Page 5957 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Specifications Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Mounting Bolt 12 ft. lbs. Page 12062 WA765J/37 - WA800J/98 Specifications Oil Pressure Sensor: Specifications Oil Pressure Sensor 15 ft. lbs. Heater Case/Cover Replacement Heater Core: Service and Repair Heater Case/Cover Replacement HEATER CORE COVER REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the screws from the heater core cover-auxiliary (3). 3. Remove the heater core cover-auxiliary (3). INSTALLATION PROCEDURE 1. Install the heater core cover-auxiliary (3). 2. Install the screws to the heater core cover-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to ......2 N.m (18 lb in). 3. Install the right rear quarter trim panel. Coupling Replacement - Antenna Inner Global Positioning System Antenna: Service and Repair Coupling Replacement - Antenna Inner COUPLING REPLACEMENT - ANTENNA INNER REMOVAL PROCEDURE 1. Disconnect the coaxial cable from the inner coupling of the mobile communication antenna (1). IMPORTANT: The adhesion promoter must be used to assure adequate bonding of the coupling. - To obtain maximum adhesion between the new cellular antenna couplings and the glass surface, the cellular antenna couplings and the glass must be kept dry and above 15°C (60°F) during the installation, and for 24 hours immediately following the installation. Otherwise the new couplings may not remain on the glass. - Do not attempt to reinstall the original couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Use a thin, wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling. NOTE: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. IMPORTANT: If the vehicle is equipped with diversity antennas, move the thin, wide-bladed plastic tool in the direction away from the antenna grid lines (2). INSTALLATION PROCEDURE 1. Clean the inside of the back glass with alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. 3. Apply Glass Adhesion Promoter GM P/N 12378555 (Canadian P/N 88901239) to the back glass in the area the antenna coupling is to be installed. Follow the Glass Adhesion Promoter instructions on the product label. Page 12547 Abbreviations And Meanings Part 15 Page 9331 Page 3698 Camshaft Position (CMP) Sensor Luggage Carrier Replacement Luggage Rack: Service and Repair Luggage Carrier Replacement Luggage Carrier Replacement Removal Procedure 1. Using a flat bladed tool, carefully remove the finish covers (3) from the luggage carrier side rails (2). 2. Unlock the cross rails (4) by releasing the locking tab (1) on the end of each cross rail. 3. Slide the cross rails forward and remove from the side rails. 4. Remove the bolts that retain the side rails to the roof panel. 5. Remove the side rails from the roof panel. Installation Procedure 1. Position the side rails (2) to the roof panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts which retain the side rails to the roof panel, starting with the rearmost bolt first on each side. Tighten the luggage carrier side rail bolts to 5 N.m (44 lb in). Important: Ensure that the loops on the cross rails are indexed toward the front of the vehicle. 3. Install the cross rails (4) to the side rails. 4. Lock the cross rails to the slide rails. 5. Install and secure the finish covers (3) to the side rails. Page 5313 Tighten the nut to 10 N.m (89 lb in). 19. Reposition the A/C line into place. 20. Install the A/C line bracket to the oil level indicator tube stud and secure the bracket with the nut. 21. Install the A/C line bracket to the engine lift bracket and secure the A/C bracket with the bolt. Tighten ^ Tighten the A/C line bracket nut to 7 N.m (62 lb in). ^ Tighten the A/C bracket bolt to 10 N.m (89 lb in). 22. Reinstall the air cleaner outlet duct. 23. Install the new fluid level indicator, P/N 15069769. 24. Check the transmission fluid level. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 3928 Abbreviations And Meanings Part 15 Ignition System - MIL ON/Misfire DTC's In Wet Weather Cowl Moulding / Trim: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 13253 Conversion - English/Metric Part 1 Page 12814 Conversion - English/Metric Part 1 Page 7723 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4636 3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure. 4. Install the retainer to the quick-connect fitting. Locations Electronic Components Page 16 Page 3303 3. Remove the heater outlet hose (3) from the heater core (1). 4. Position the outlet heater hose clamp (6) at the water pump using J 38185. 5. Remove the heater outlet hose (7) from the outlet hose fitting. 6. Remove the heater outlet hose. INSTALLATION PROCEDURE A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: All Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Steering - Hissing Noise From Steering Column Steering Shaft: All Technical Service Bulletins Steering - Hissing Noise From Steering Column Bulletin No.: 05-02-35-006A Date: October 04, 2005 TECHNICAL Subject: Hiss/Rush Noise From Steering (STRG) Column Area (Replace Lower Intermediate Shaft) Models: 2004-2005 Buick Rainier Models 2002-2005 Chevrolet TrailBlazer Models 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada Models Supercede: This bulletin is being revised to correct the Labor Operation Number. The original bulletin incorrectly states to use Labor Operation E7770. The correct Labor Operation is E7700. Please discard Corporate Bulletin Number 05-02-35-006 (Section 02 - Steering). Condition Some customers may comment on a low volume hiss and/or rush noise heard from the steering column area. The noise may change when the steering wheel is rotated in either direction. The noise may be noticeable with the engine ON, vehicle in PARK, HVAC and Radio OFF. Cause The lower steering column intermediate shaft may be internally grounding out, creating a noise path. Diagnosis and Correction To determine if the lower intermediate shaft is allowing noise to travel from the power steering hydraulic system into the vehicle passenger compartment, follow the steps below. 1. Confirm the customer's concern. Note: Page 11253 8. Open the hood and install the prop rod. 9. Install the left and right adjustable rubber bumpers and adjust them all the way down. 10. Close the hood and verify adjustment. The bumpers are required to make contact with the hood. Adjust if necessary. 11. Apply white lithium grease to the bottom of the V on the latch. Refer to illustration above. 12. Verify the final adjustment by grabbing the hood and jiggling it up and down. If a rattle is heard, perform the procedure again. 13. Install the grille. Refer to Grille Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10673 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 4153 Data Link Connector (DLC) Diagram 2 Page 9824 Abbreviations And Meanings Part 16 Page 7238 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 7375 Fuse Block: Application and ID Underhood Fuse Block Location View Application Table Part 1 Page 10367 Abbreviations And Meanings Part 20 Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Adjustments Trunk / Liftgate Striker: Adjustments Striker Adjustment - Lift Gate Window Adjustment Procedure 1. Check the lift gate window for proper fit to the lift gate window weather-strip. * Open and close the lift gate window. * If the lift gate window is hard to close, additional striker shims will need to be added. * If the lift gate window does not seal tightly against the weather-strip, striker shims will need to be removed. 2. Open the lift gate window. 3. Loosen the nuts retaining the lift gate striker to the lift gate window. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove or add shims as determined above. Tighten the lift gate window striker nuts to 6 N.m (53 lb in). 5. Check the lift gate window for proper fit, readjust if necessary. 6. Close the lift gate window. Page 6355 7. Remove the rear brake caliper from the brake caliper mounting bracket. Installation Procedure 1. If the brake caliper guide pin is to be reused, clean the brake caliper guide pin using denatured alcohol, or equivalent. 2. Dry the brake caliper guide pin using non-lubricated, filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper guide pin. DO NOT apply lubricant to the brake pad hardware. 4. Install the rear brake caliper assembly to the mounting bracket. Page 3159 29. Install the auxiliary heater pump and bracket onto the dash panel studs. 30. Reinstall the HVAC plate and nuts. 31. On the coolant bypass valve, remove the hose (1) that went from the valve to the engine and discard. Page 5896 Flex Plate: Specifications Flywheel to Torque Converter bolts .......................................................................................................................................................... 60 Nm (44 ft.lbs.) Page 9810 Abbreviations And Meanings Part 2 Camshaft Actuator System Camshaft Position Sensor: Description and Operation Camshaft Actuator System CAMSHAFT POSITION (CMP) ACTUATOR SYSTEM The Camshaft Position Actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation control, a wider engine torque range, improved gas millage, and improved engine idle stability. The CMP Actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. CMP ACTUATOR SYSTEM OPERATION The CMP Actuator system is controlled by the Powertrain Control Module (PCM). The PCM sends a pulse width modulated 12 volt signal to a Camshaft Position (CMP) Actuator Solenoid in order to control the amount of engine oil flow to a cam Phaser passage. There are two different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The Cam Phaser is attached to a camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position. Engine oil pressure, viscosity, temperature and engine oil level can have an adverse affect on cam phaser performance. The PCM calculates the optimum cam position through the following inputs: Engine Speed - Manifold Absolute Pressure (MAP) - Throttle Position (TP) Indicated Angle - Crankshaft Position (CKP) - Camshaft Position (CMP) - Engine Load. - Barometric (BARO) Pressure The Cam Phaser default position is 0 degrees. The PCM uses the following inputs before assuming control of the cam phaser: Engine Coolant Temperature (ECT) - Closed Loop Fuel Control - Engine Oil Temperature - Engine Oil Pressure - Engine Oil Level - CMP Actuator Solenoid circuit state - Ignition 1 signal voltage - Barometric (BARO) Pressure CMP ACTUATOR SOLENOID CIRCUIT DIAGNOSTICS The PCM monitors the control circuits of the CMP Actuator Solenoid for electrical faults. The PCM has the ability to determine if a control circuit is open, shorted high, and shorted low. If the PCM detects a fault with a CMP Actuator Solenoid circuit a Diagnostic Trouble Code (DTC) will set. CMP ACTUATOR SYSTEM PERFORMANCE DIAGNOSTICS The PCM monitors the performance of the CMP Actuator system by monitoring the actual and desired positions of a cam phaser. If the difference between the actual and desired position is more than a calibrated angle for more than a calibrated amount of time, a DTC will set. Page 13434 Page 12661 Liftglass Ajar Switch Page 12612 Position Sensor - Horizontal Motor (w/Memory) Page 9663 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 10855 Conversion - English/Metric Part 1 Page 2557 13. Inspect the piston, piston rings, and connecting rod for damage. Refer to Piston, Connecting Rod, and Bearings Cleaning and Inspection. Cylinder Bore Sleeve Installation Note: Do not use assembly aids or lubricants on the cylinder bore sleeve or the cylinder bore block when installing a new cylinder bore sleeve, or engine damage will occur. These items will not aid in the installation of the new cylinder bore sleeve. Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. 1. Place the NEW cylinder bore sleeve (117), PIN 88984239, onto the cylinder block. 2. Install fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1), which is part of EN 45680-400,over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117). Important: Use 4 old cylinder head bolts for the attaching bolts. 3. Insert the 4 attachment bolts into the legs of the fixture EN 45680-401(1). 4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore sleeve (117). Tighten Tighten the 4 attachment bolts to 15 Nm (11 lb ft). Page 9189 Abbreviations And Meanings Part 22 Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 10041 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 7644 ^ The pressure hose O-rings ^ The gear cylinder line O-rings ^ The reservoir to pump O-ring 9. Repeat the bleed procedure from the beginning. 10. Drive the vehicle approximately 16 km (10 miles) in order to warm the system to operating temperature. Evaluate vehicle on a smooth flat surface. 11. Verify the following conditions: ^ There is smooth power assist. ^ The vehicle operates quietly. ^ The pump maintains the proper fluid level. ^ There is not any leaking in the steering system. ^ The fluid is free of foam or discoloration. Page 1250 Cabin Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2 wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and low reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0-5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the following conditions: The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 13403 For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a Campaign Initiation Detail Report. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Page 10792 Steering Wheel Controls Page 13193 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 12471 Removal Procedure 1. Remove the seat from the vehicle. 2. Remove the rear seat bracket trim covers (1). 3. Remove the rear seat cushion bracket mounting nuts (2). 4. Remove the rear seat cushion bracket. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the rear seat cushion bracket to the seat cushion bottom with the four mounting nuts (2). Tighten the rear seat cushion bracket mounting nuts to 25 N.m (18 lb ft). 2. Install the rear seat bracket trim covers (1). 3. Install the seat in the vehicle. Seat Cushion Latch Release Assembly Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada) Seat Cushion Latch Release Assembly Replacement - Rear No. 1 (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the rear seat cushion assembly from the vehicle. 2. Remove the rear-seat cushion cover and the pad. 3. Remove the strap (1) from the rear seat cushion latch (2). Procedures Head Rest: Procedures Head Restraint Replacement - Front Seat HEAD RESTRAINT REPLACEMENT - FRONT SEAT REMOVAL PROCEDURE 1. Raise the head restraint to the full up position by pressing the release tab (2), and by lifting up the head restraint. 2. Insert a small tool into the head restraint retainer port (1). 3. In order to release the head restraint retainer, simultaneously lift up on the head restraint while applying inward pressure to the tool in the retainer release port (1). 4. Remove the head restraint from the seat assembly. INSTALLATION PROCEDURE 1. Position the head restraint to the seat assembly. 2. Verify that the notches in the head restraint posts are indexed toward the rear of the seat assembly. 3. Push the head restraint downward into the fully installed position. 4. Raise the head restraint to the full up position. Verify that the head restraint retainer prevents the head restraint from being removed from the seat assembly. Head Restraint Guide Replacement - Front Seat HEAD RESTRAINT GUIDE REPLACEMENT - FRONT SEAT REMOVAL PROCEDURE 1. Remove the front seat assembly. 2. Remove the front seat head restraint. Page 6197 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Connector Views Fuse Block: Connector Views Fuse Block - Rear C1 Fuse Block - Rear C1 Part 1 Page 1671 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 13157 Registered And Non-Registered Trademarks Part 3 Page 8493 Steering Wheel Controls Page 5834 21. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 22. Install the differential. 23. Perform a gear tooth contact pattern check on the pinion and the ring gear. 24. Install the axle shafts. 25. Install the brake rotors. 26. Install the brake calipers. 27. Install the tire and wheel assemblies. 28. Fill the axle with axle lubricant. Use the proper fluid. 29. Lower the vehicle. A/T - Oil Cooler Flushing/Flow Check Procedures Transmission Cooler: All Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Page 1192 Engine Coolant Temperature (ECT) Sensor Page 4266 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 4940 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Page 7242 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 5412 Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side Page 12398 Lumbar Adjuster Switch - Passenger (w/o Heat) Page 10310 Page 3532 Body Control Module: Removal and Replacement Body Control Module Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the BCM on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. Page 470 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Service and Repair Memory Positioning Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the 3 seat switch bezel screws. 2. Remove 4 nuts that attach the seat pan to the seat assembly. 3. Remove the clip from the front outboard seat pan stud. Discard the clip. 4. Lift the seat pan up in order to allow access to the seat control module retaining screw. 5. Remove the seat control module retaining screw. 6. Disconnect the electrical connectors from the seat control module as necessary. 7. Remove the seat control module from the seat assembly. INSTALLATION PROCEDURE 1. Align and install the locating tabs on the seat control module with the seat pan. 2. Connect the electrical connectors to the seat control module as necessary. Page 10655 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Body - Door(s) Are Difficult To Close Front Door Striker: Customer Interest Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Page 3457 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 12546 Abbreviations And Meanings Part 14 Diagrams Headlamp Motor: Diagrams Headlamp Leveling Actuator - Left (With RPO Code TR6) Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Page 13867 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 1817 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Page 825 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 9842 Garage Door Opener Diagrams Cargo Lamp: Diagrams Cargo Lamp Page 607 Abbreviations And Meanings Part 19 Page 12887 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 12888 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 9282 8. Remove the radio antenna cable assembly retaining screws. 9. Pass the antenna cable and grommet assembly through the fender opening. 10. Remove the radio antenna cable assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the radio antenna cable assembly to the vehicle. 2. Pass the antenna cable and grommet assembly through the fender opening. 3. Install the radio antenna cable assembly retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the radio antenna cable assembly screws to 2.8 N.m (25 lb in). 4. Close the hood. 5. Install the antenna mast. Page 11042 9. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge. Installation Procedure 1. Position the service hinge within the scribe marks on the hinge pillar. 2. Mark each hole location on the hinge pillar according to the service hinge. 3. Drill a 3 mm (1/8 in) pilot hole at each marked location (1). 4. Drill a 13 mm (1/2 in) hole at each pilot hole location (2). 5. Clean and prepare all bare-metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-2001 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an anti-corrosion primer. Page 36 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 9900 Page 13568 Page 4118 Abbreviations And Meanings Part 4 Page 13557 Page 5453 Disclaimer Page 8860 Disclaimer Page 1601 Ride Height Sensor: Service and Repair Air Spring Leveling Sensor Replacement Removal Procedure Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensor to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Ensure that the vehicle is parked on level surface. 3. Inspect tires for proper tire pressure. 4. Inspect the air suspension system components for damage or defects. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the rear tire and wheels. 7. Support the rear axle and set the rear axle to proper D height. 8. Disconnect the air spring level sensor link from the upper control arm. 9. Disconnect the air spring level sensor electrical connector. Page 12779 Page 3507 Abbreviations And Meanings Part 24 Page 8997 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the grille. 6. Remove sensor bracket from bumper. 7. Remove the Connector Position Assurance (CPA) from both (2) electronic frontal sensor (EFS) connectors. IMPORTANT: This vehicle is equipped with two inflatable restraint electronic frontal sensors (EFS). When performing this procedure be sure to include both EFS's. 8. Disconnect both EFS connectors. Zone 2 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 939 Engine Harness, Fuse Block-Underhood Page 13257 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 6114 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four new T-25 TORCH screws (1) in the EBCM (2). ^ Tighten the four T-25 TORX screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM (2). 4. Revise the tire calibration using the Scan Tool Tire Size Calibration function. Page 12247 Endgate Module (EGM) C2 (XUV) Part 2 Page 2337 - For vehicles with dual rear wheels (different tire sizes and load ranges), rotate the tires as shown. - For vehicles with dual rear wheels (including the spare tire), rotate the tires as shown. Diagrams Fuel Pump And Sender Assembly Page 795 Relay Box: Service and Repair Rear Electrical Center or Junction Block Replacement REAR ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a cargo position. 4. Remove the rear electrical center cover. 5. Remove the battery feed terminal nut (2) from the junction block. 6. Remove the body control module (BCM) from the rear electrical center. 7. Fully loosen the 3 bolts (1) that retain the junction block to the electrical connectors. Page 8868 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the A/C low pressure switch electrical connector. 2. Remove the A/C low pressure switch (2) from the accumulator (1). 3. Remove and discard the O-ring seal from the A/C low pressure switch port on the accumulator. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the A/C low pressure switch (2) to the accumulator (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the A/C low pressure switch to 4.8 N.m (42 lb in). 3. Connect the A/C low pressure switch electrical connector. 4. Leak test the fittings of the components using the J 39400-A. Page 3281 Coolant Bypass Valve (Body Type VIN 6) (w/Automatic - HVAC System) Knock Sensor (KS) 1 Front Knock Sensor (KS) 1 Front Page 1020 40.1. Install the ring terminal (black wire) to ground G103 (1), located on the right side inner tender. 40.2. Route the pump wiring harness along the existing right side forward lamp harness. 40.3. Connect the electrical connectors to the coolant bypass valve (1) and auxiliary heater pump (2). 40.4. Position the relays onto the inner wheelhouse panel near the rear of the engine compartment. Page 8225 Mode Actuator - Auxiliary (Body Type VIN 3) Page 13201 Odometer: Technical Service Bulletins Instruments - Odometer/Hour Meter Programming Procedure INFORMATION Bulletin No.: 07-08-49-015D Date: May 04, 2010 Subject: Information on Instrument Panel Cluster (IPC) Odometer and Engine Hour Meter Set Up at Dealership After IPC Replacement Models: 2004-2007 Buick Rainier 2003-2006 Cadillac Escalade Models 2002-2009 Chevrolet TrailBlazer 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 Chevrolet Silverado Classic (12th Digit of VIN 1 or 2) 2002-2009 GMC Envoy 2003-2006 GMC Sierra, Yukon Models 2007 GMC Sierra Classic (12th Digit of VIN 1 or 2) 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2009 Saab 9-7X Attention: The purpose of this bulletin is to inform dealership personnel that the Instrument Panel Cluster (IPC) odometer and engine hour meter (when applicable) setting will no longer be performed at an Electronic Service Center (ESC). Dealerships will now receive IPCs with the odometer and engine hour meter not programmed. The technician will be required to note the odometer reading and engine hour (when applicable) values of the original IPC, then use the SPS application to program these values into the new IPC. Supercede: This bulletin is being revised to update the text in Steps 1, 2, 3, 4, 5, 6 and 7. Please discard Corporate Bulletin Number 07-08-49-015C (Section 08 - Body and Accessories). Background Information Previous IPC replacement procedures specify that the odometer and engine hour values be communicated to and programmed by the Electronic Service Centers (ESC) into the replacement IPC at the time the replacement is ordered. This required the vehicle to be parked after the replacement IPC is ordered so that no additional mileage can be accumulated on the vehicle while the new IPC is in transit to the dealership. Improvements to the TIS2WEB SPS application will now allow IPC odometer and engine hour programming to be performed as an additional function of the IPC programming event. This new process will allow the vehicle to be returned to the customer, if necessary, and driven while waiting for the replacement IPC to arrive at the dealership. Odometer and engine hour values will no longer be communicated to the ESC for programming purposes but ESCs still need the odometer value for warranty reporting. Dealerships will now receive a replacement IPC with the odometer and engine hour values NOT programmed. The technician will be required to note the odometer and engine hour values of the original IPC, then use the TIS2WEB SPS application to program these values into the replacement IPC. The odometer and engine hour programming will now be included as a normal part of the IPC replacement procedure in SI. Odometer and Engine Hour Programming Procedure Information - If the original IPC odometer value cannot be obtained from the customer's vehicle, follow local and federal regulations regarding unknown odometer mileage situations. - Because the odometer and engine hour values can now be read from the original IPC and programmed into the replacement IPC during the same visit, the customer's vehicle will no longer need to be parked until the replacement IPC is received from an ESC. - Avalanche, Escalade, Sierra, Silverado, H2, Suburban, Tahoe and Yukon vehicles will also require the engine hour data to be recorded for transfer to the replacement IPC. The replacement IPC may already have engine hours showing. This does not affect the IPC Setup procedure. Bravada, Envoy, Rainier and TrailBlazer vehicles do not support the calculation or display of engine hour data. - Ensure that the correct odometer value is entered when prompted. Once programming is complete, the odometer and engine hour values, when applicable cannot be changed. - By default, the application odometer entry will be set to: miles. For metric units, click the button on the left next to: Kilometers. Service Procedure Important The replacement IPC requires IPC Setup procedures and SPS programming to be performed. Legacy Pass-Thru will no longer be Page 5138 3. Install the 1-2 and 2-3 Shift solenoids. 4. Install the 1-2 and 2-3 Shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. Page 2328 Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Page 6186 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 9421 Page 853 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 709 Electronic Brake Control Module: Specifications EBCM to BPMV 39 inch lbs. Page 12373 Seat Horizontal Motor - Driver/Passenger Page 2710 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 4211 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). 4. Lower the vehicle. Page 829 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Specifications Air Line: Specifications Air Supply Lines to Air Spring Compressor 20 inch lbs. Page 41 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 2163 Brake Bleeding: Service and Repair Manual Bleeding Procedure Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7- 11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Page 9396 Registered And Non-Registered Trademarks Part 4 Page 7565 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 12138 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 9055 4. Adjust the seat filler panel in order to access the center rear seat back bracket/seat belt buckle anchor plate. 5. Install the center seat back/seat belt buckle mounting nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the center rear seat back mounting nut to 45 N.m (33 lb ft). 6. Return the seat to an upright position. Buckle Replacement - Center Rear (TrailBlazer EXT, Envoy XL) REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the trim panel from the seat cushion. 3. Remove the bolt (1) securing the center buckles to the mid-position floor latch assembly. 4. Remove the center seat belt buckles. INSTALLATION PROCEDURE 1. Install the center seat belt buckles to the mid-position floor latch assembly with the bolt (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear center seat belt buckle assembly bolt to 60 N.m (44 lb ft). 2. Install the trim panel to the seat cushion. 3. Install the seat in the vehicle. Page 7990 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Page 12497 Page 8125 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Step 1 - 4 Wheel Bearings Diagnosis Step 5 - 7 Page 13133 Abbreviations And Meanings Part 5 Specifications Parking Brake Lever: Specifications Park Brake Lever Mounting Nuts 18 ft. lbs. Page 11817 Abbreviations And Meanings Part 2 Page 6778 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 12748 4. Install the rear door sill plate. Page 3161 33. Install the new hose, # 1003 (L6 engine) or # 1004 (V8 engine) onto the auxiliary heater pump inlet port. Connect the other quick connect end to the engine. Page 4106 Conversion - English/Metric Part 2 Page 3513 Registered And Non-Registered Trademarks Part 4 Entertainment System - Headphone Foam Pad Replacement Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam Pad Replacement Bulletin No.: 05-08-44-005A Date: July 19, 2007 INFORMATION Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2, H3 2005-2008 Saab 9-7X with Rear Seat Entertainment System (RPOs U32, U42) Supercede: This bulletin is being revised to add models and model years and update the shipping costs. Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories). Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear pads may wear out when not handled and stored carefully. If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced separately from the headphone set. It is not necessary to replace the complete headphone set. Parts Information All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. The headphone replacement foam ear pads can be ordered in pairs directly through the supplier. Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping. Disclaimer Page 1840 Steps 1-3 Page 12120 Diagrams Trunk / Liftgate Switch: Diagrams Liftgate Ajar Switch Page 10492 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 11996 For vehicles repaired under warranty use, the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty use, the table. Page 11119 9. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge. Installation Procedure 1. Position the service hinge (1) within the scribe marks (2) on the hinge pillar (3). 2. Mark each hole location on the hinge pillar according to the service hinge. 3. Drill a 3 mm (1/8 in) pilot hole at each location (1). 4. Drill a 13 mm (1/2 in) hole at each pilot hole location (2). 5. Clean and prepare all bare-metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-2001 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an anti-corrosion primer. Page 1717 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 13972 Heated Glass Element: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS - HEATED GLASS ELEMENT IMPORTANT: For the inside rearview mirror with the automatic day-night feature, review the system operation in order to familiarize yourself with the system functions. Refer to Automatic Day-Night Mirror Description and Operation. For the rear window defogger system, the following steps must be performed before using the symptom tables: 1. Perform the Diagnostic System Check - Defogger before using the symptom tables in order to verify that all of the following are true: - There are no DTCs set. - The control modules can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Defogger 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Rear Window Defogger Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the rear window defogger or the automatic day-night feature of the inside rearview mirror. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Defogger Inoperative - Rear Window - Defogger Grid Lines Diagnosis - Mirrors - Automatic Day-Night Inoperative - Mirrors - Temperature Displays SC or OC - Mirrors - Compass Display Inoperative or Inaccurate Automatic Day/Night Mirror Inoperative - Mirrors MIRRORS - AUTOMATIC DAY-NIGHT INOPERATIVE DIAGNOSTIC AIDS The automatic day-night feature of the inside rearview mirror may not operate properly or become inoperative due to an intermittent short to battery voltage in the backup lighting system. TEST OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 12059 WA605H/45 - WA711J/58 Page 342 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Interior - Proper Use of Floor Mats Carpet: All Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Page 3985 Engine Coolant Temperature (ECT) Sensor Page 5675 Electronic Components Page 4134 Abbreviations And Meanings Part 20 Page 86 Registered And Non-Registered Trademarks Part 5 Page 10422 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Engine - Redesigned Oil Pick-Up and Front Cover Oil Pick Up/Strainer: Technical Service Bulletins Engine - Redesigned Oil Pick-Up and Front Cover Bulletin No.: 04-06-01-015 Date:May 24, 2004 INFORMATION Subject: New Design Oil Pick Up Tube and Front Cover Models: 2004 Buick Rainier 2002-2004 Chevrolet Trailblazer 2002-2004 GMC Envoy 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Page 10427 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 7151 Application Table Part 4 Location View Page 3635 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Page 2948 Abbreviations And Meanings Part 20 Page 4793 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 1725 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Locations Electronic Components Page 3539 2. Connect the 24-way gray electrical connector (1) to the BCM. 3. Connect the 32-way tan electrical connector (2) to the BCM. 4. Connect the body wiring extension (1) to the BCM. 5. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. Page 6328 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 1038 16. Inspect the inside of the electrical connector on the wiper motor for moisture or water. If no moisture or water is found, continue inspecting for evidence or signs that moisture or water was present at some earlier time. Indicators include water stains, dried dirt, etc. (1). ^ If moisture or water is found in the electrical connector, or if there is evidence that there was moisture or water present at an earlier time, the complete wiper motor module (including the motor) MUST be replaced. Obtain a new wiper module and proceed to Step 20. The new wiper modules already have a different style of breathable seal on the wiper cover. DO NOT install the breathable seal described later in this recall on new wiper modules. ^ If there is no moisture or water found in electrical connector, or if there is NO evidence that moisture or water was present at an earlier time, a breathable seal must be installed over the vent in the wiper motor cover. Proceed to the next step. 17. Clean the exterior surface of the wiper motor cover thoroughly (1). It must be free of dirt, grease, oil, and other contamination. Important To ensure good adhesion of the seal being installed in the next steps, make sure that your hands are clean and free of oil and grease before proceeding. 18. Using the alcohol wipe included in the kit, wipe the complete exterior surface of the wiper cover thoroughly. Allow the surface to dry approximately 30-45 seconds before proceeding. Important When using the adhesion promoter in the next step: ^ DO NOT open the adhesion promoter until you are ready to apply it. ^ Use the complete contents of the packet as soon as it is opened. ^ If the packet is dried-out when opened, obtain another sealer kit or use P/N 12378462 (4 oz. can of adhesion promoter). ^ Do not allow the liquid to "spill" inside of the vent opening on the wiper motor cover when applying. ^ Allow to dry 30-90 seconds before applying the seal. 19. Carefully apply the adhesion promoter that is included in the kit. Important The seal must be inspected before installing. If there are any creases in the seal or backing material, the seal must NOT be used. Obtain another sealer kit. ^ If you are unable to remove the backing material from the seal in the next step, the seal is beyond its shelf life of one year. Obtain another sealer kit. Do NOT touch the adhesive surface on the seal when removing the backing material. Page 328 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 6432 Submit a Product Recall Claim with the information shown CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter shown. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Page 547 Page 7835 Control Arm: Specifications Rear Axle Upper Control Arm Mounting Bolts 96 ft. lbs. Page 12795 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 6825 Registered And Non-Registered Trademarks Part 3 Body VIN 3 / GMT 360 Expansion Block/Orifice Tube: Service and Repair Body VIN 3 / GMT 360 EXPANSION (ORIFICE) TUBE REPLACEMENT (BODY VIN CODE 3) TOOLS REQUIRED - J 26549-E Orifice Tube Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Remove the accumulator. 3. Remove the coolant reservoir. 4. Remove the evaporator tube nut (3) at the evaporator (1). 5. Remove the evaporator tube (4) from the evaporator (1). 6. Remove the O-ring seal and discard. 7. Remove the nut from the evaporator tube block fitting. 8. Separate the evaporator tubes (4,6) at the block fitting. 9. Use the J 26549-E in order to remove the expansion tube. 10. Remove the expansion tube from the evaporator tube (6). INSTALLATION PROCEDURE Page 3304 1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185. 4. Install the heater outlet hose (3) to the heater core (1). 5. Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Install the transmission. 7. Install the coolant bypass valve. Page 13938 Abbreviations And Meanings Part 8 Locations Steering Column Page 11806 Conversion - English/Metric Part 1 Page 1159 Liftglass Ajar Switch Page 3487 Abbreviations And Meanings Part 4 Body - Front Bumper Fascia Panel Wavy Front Bumper Cover / Fascia: All Technical Service Bulletins Body - Front Bumper Fascia Panel Wavy Bulletin No.: 02-08-62-004B Date: June 02, 2006 TECHNICAL Subject: Front Fascia Wavy (Install Dual Lock) Models: 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer EXT LS Model 2006-2007 Chevrolet TrailBlazer LS, TrailBlazer SS Supercede: This bulletin is being revised to add model years and material allowance. Please discard Corporate Bulletin Number 02-08-62-004A (Section 08 - Body and Accessories). Condition Some customers may comment that the front fascia is wavy under the grille or under the front turn signals. Refer to the illustration above. Correction 1. Remove the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. 2. Remove the impact bar from the front fascia. 3. Remove the hot melt on the top of the impact bar. 4. Clean and scuff the impact bar with a scotch bright pad. 5. Apply a coating of GM Adhesion Promoter, P/N 12378462 (Canadian P/N 10953554), to the top surface of the impact bar and let dry. 6. Install 3M Dual Lock, P/N 06463, to the impact bar as shown in the illustration above. 7. Clean the fascia and apply the Adhesion Promoter to the fascia. 8. Install the impact bar to the fascia. 9. Install the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. Page 2834 Registered And Non-Registered Trademarks Part 6 Page 7743 6. Place the larger cylinder line (2) into the valve housing (3). Important: Hold the larger cylinder line (2) in place. Do not torque the cylinder line nut (1). 7. Place the other end of the cylinder line at the gear tube end (4). Finger tighten the cylinder line nut (1) on the larger cylinder line. 8. Place the cylinder line retaining plate (2) over the cylinder line beads at the valve end. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the TORX screw (1) into the cylinder line retaining plate (2) and tighten using an E 8 socket. Tighten the screw to 15 Nm (12 ft. lbs.). 10. Tighten both cylinder line nuts (3) at the cylinder end. Tighten the nuts to 31 Nm (23 ft. lbs.). Page 6145 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II00, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. A/T - 4L60/65E, No Reverse/2nd or 4th Gear Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 6829 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 10917 7. Install the rear electrical center cover. 8. If replacing the BCM on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 9. If replacing the BCM on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 10. Connect the negative battery cable. 11. If installing a replacement BCM, program the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Body Wiring Harness Extension Replacement - BCM BODY WIRING HARNESS EXTENSION REPLACEMENT - BCM REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the body wiring harness extension on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the body wiring harness extension on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. Locations Engine, Left Side Page 4000 Splice Pack SP306 Page 13927 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 4087 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 8105 Disclaimer Page 11039 10. Torque all four bolts to 25 N.m (18 ft.lb). 11. Clean and prepare all bare-metal surfaces. 12. Apply a full-bodied caulk around the service hinge. 13. Refinish as necessary. 14. Install and align all of the related panels and components. Page 8510 HVAC Control Module-Auxiliary, With Rear Seat Audio (Body Type VIN 6) Part 1 Page 616 Registered And Non-Registered Trademarks Part 2 Page 8226 Mode Actuator - Auxiliary (Body Type VIN 6) Page 3636 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the fuel tank pressure harness connector. 3. Remove the fuel tank pressure sensor. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor seal. 2. Install the fuel tank pressure sensor. 3. Connect the fuel tank sensor harness connector. 4. Lower the vehicle. Page 9347 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 10513 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 10302 Page 5187 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Page 7976 Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Revised Shock Module Replacement Bulletin No.: 06-03-08-011 Date: August 28, 2006 SERVICE MANUAL UPDATE Subject: Revised Shock Module Replacement Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer Models 2002-2007 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X This bulletin is being issued to revise the Shock Module Replacement procedure in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The recommended tool to use is J 36607 instead of J 24319-B. Shock Module Replacement Tools Required J 36607 Ball Joint Separator Removal Procedure Remove the shock module upper retaining nuts. Page 8549 1. Connect the HVAC control-auxiliary electrical connector. 2. Install the HVAC control-auxiliary in the console bottom first. 3. Push in at the top of the HVAC control-auxiliary in order to engage the HVAC control-auxiliary in the console/seat. Page 8881 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P upper trim pad. 2. Remove the sun load sensor from the I/P upper trim pad by turning counter clockwise. 3. Disconnect the electrical connector from the sun load sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sun load sensor. 2. Install the sun load sensor to the I/P upper trim pad by turning clockwise. 3. Install the I/P upper trim pad. Page 8395 Abbreviations And Meanings Part 15 Page 11791 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 12178 Abbreviations And Meanings Part 23 Page 13933 Abbreviations And Meanings Part 3 Page 6213 Abbreviations And Meanings Part 12 Locations Engine, Left Side Page 12876 Page 6737 For vehicles repaired under warranty, use the table. Disclaimer Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioner Bolt 18 ft. lbs. Page 6640 Page 3498 Abbreviations And Meanings Part 15 Page 7500 C500 Part 2 Page 3521 Body Control Module (BCM) C1 Part 3 Page 9324 Page 12421 1. Install the latch release cable to the right-hand hinge bracket. 2. Install the seat belt retractor assembly, on the left side only. 3. Install the seat back hinge brackets. 4. Install the head restraint retractor assembly. 5. Install the latch release assembly. 6. Install the latch release cables (1) and the head rest restraint cable (2) to the left-hand hinge bracket. 7. Install the seat back cover and pad. Page 8260 REMOVAL PROCEDURE 1. Remove the HVAC module assembly. 2. Remove the floor air outlet duct retaining screws (2,3,4). 3. Remove the RH side floor air outlet duct (1). INSTALLATION PROCEDURE 1. Install the floor air outlet duct (1) into position. 2. Install the floor air outlet duct retaining screws (2,3,4). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to .....1.9 N.m (17 lb in). 3. Install the HVAC module assembly. Page 13889 Body - Rattle Under Hood Hood Support Rod: Customer Interest Body - Rattle Under Hood Bulletin No.: 04-08-63-005 Date: June 15, 2004 TECHNICAL Subject: Rattle Noise Under Hood (Reposition Hood Prop Rod) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on a slight buzz or rattle noise coming from under the hood. This noise could be mistaken for a unusual engine noise. Cause The hood prop rod may be making contact with the fan shroud. Correction Adjust the hood prop rod. 1. Support the hood. 2. Make sure the plastic prop rod pivot block is fully seated into the radiator support before making the adjustment. 3. Adjust the prop rod by bending the rod at the point of contact. Refer to the arrow in the illustration above. There should be approximately 10 mm (3/8 in) between the prop rod and the shroud. Warranty Information For vehicles repaired under warranty, use the table. Page 7383 4. Install the harness end bolts (2). 5. Install the fuse relay center cover (1) over the relay center bolts. Press downward to engage the tabs. 6. Install the junction block cover. Press downward to engage the tabs. OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 11011 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Page 13428 Page 1766 Registered And Non-Registered Trademarks Part 4 Page 6608 Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. Heated Oxygen Sensor (HO2S) 2 Heated Oxygen Sensor (HO2S) 2 Locations Accelerator Page 13312 Door Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the rear door ajar switches in the door lock assemblies as one method to activate the alarm. The body control module (BCM) monitors rear door ajar switches via a discrete input from each rear passenger door ajar switch, if the BCM receives a ground signal from a rear passenger door ajar switch when the CTD system is armed, the BCM activates the alarm. The CTD system uses the LH front door ajar switch as one method to activate the alarm. The driver door module (DDM) monitors the LH door ajar switch via a discreet input from the door ajar switch, if the DDM receives a ground signal from the LH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the RH front door ajar switch as one method to activate the alarm. The passenger door module (PDM) monitors the RH door ajar switch via a discreet input from the door ajar switch, if the PDM receives a ground signal from the RH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the rear compartment liftgate/liftglass ajar switchs as one method to activate the alarm. The liftgate module (LGM) monitors the liftgate and liftglass ajar switch via a discreet input from the ajar switch, if the LGM receives a ground signal from the liftgate or liftglass ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. Page 9344 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 7770 5. With the applicator hose down as far as possible toward the mating area of the serrations, spray a generous amount of grease. 6. Repeat the application after rotating the steering wheel 180 degrees, so that the serrations are treated in two locations opposite each other. 7. Position the floor air outlet duct into place and install the push pin retainer. 8. Raise the insulator panel and install the retaining clip to the IP substrate. 9. Install the two screws that retain the left closeout/insulator panel to the IP. Use the following steps to remove material from the upper intermediate shaft bushing. 1. Push the upper intermediate shaft boot seal (2) down toward the floor in order to completely expose the white bushing (1). 2. Using fine or very fine sandpaper, remove material from the intermediate shaft bushing. Sand around the entire face of the bushing sufficient enough to obtain clearance and reduce the drag between the intermediate shaft bushing and the upper boot seal. 3. Return the upper intermediate shaft boot seal to its original position. 4. Clean debris as necessary. Parts Information Warranty Information Locations Engine Page 6785 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 11833 Abbreviations And Meanings Part 18 Page 3269 Engine Coolant Temperature (ECT) Sensor Description and Operation Exhaust Resonator: Description and Operation Resonator Some exhaust systems are equipped with a resonator. The resonator, located either before or after the muffler, allows the use of mufflers with less back pressure. Resonators are used when vehicle characteristics require specific exhaust tuning. Page 7435 For vehicles repaired under warranty, use the table. Disclaimer Page 614 Abbreviations And Meanings Part 26 Page 1815 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Service and Repair Power Steering Pressure Control Valve: Service and Repair Power Steering Pump Flow Control Valve Replacement - Off Vehicle (CB Series) Disassembly Procedure 1. Remove the O-ring union fitting (5) from the hydraulic pump housing assembly (1). 2. Remove the O-ring seal (4) from the O-ring union fitting (5). 3. Remove the control valve assembly (3). 4. Remove the flow control spring (2). Assembly Procedure 1. Install the flow control spring (2) to the hydraulic pump housing assembly (1). 2. Install the control valve assembly (3). 3. Lubricate the O-ring seal (4) with power steering fluid. 4. Install the O-ring seal (4) onto the O-ring union fitting (5). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the O-ring union fitting (5) into the hydraulic pump housing assembly (1). Tighten the fitting (5) to 75 Nm (55 ft. lbs.). Page 880 Abbreviations And Meanings Part 25 Page 8060 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13964 Heated Glass Element: Connector Views Rear Window Defogger C1 Page 6247 8. Remove the brake pad retaining clips from the mounting bracket, inboard brake pad shown. 9. Remove the brake caliper mounting bracket retaining bolts, lower bolt shown. 10. Remove the brake caliper mounting bracket. Page 8639 1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185. 4. Install the heater outlet hose (3) to the heater core (1). 5. Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Install the transmission. 7. Install the coolant bypass valve. Page 13730 1. Position the headlamp switch near the access hole. 2. Connect the electrical connectors to the headlamp switch. 3. Install the headlamp switch to the IP. Ensure that the retaining tabs are fully seated. 4. Install the left IP access cover. Page 11093 4. Install the front door sill plate. Page 9057 2. Install a new grommet (1). 3. Install the seat assembly in the vehicle. Side Buckle Replacement - Rear REMOVAL PROCEDURE 1. Adjust the rear seats and seat backs to a cargo position. 2. Loosen the center seat belt anchor bolt that retains the seat belt to the seat belt buckle/anchor plate assembly. 3. Remove the left rear seat back rear mounting nut that retains the left seat back to the floor panel. 4. Remove the assembly clip that retains the seat belt buckle/anchor plate assembly to the rear seat back hinge bracket. 5. Remove the seat belt buckle and anchor plate assembly from the rear seat back hinge bracket. 6. Remove the center seat belt anchor bolt from the seat belt buckle/anchor plate assembly. 7. Remove the center seat belt anchor from the seat belt buckle/anchor plate assembly. INSTALLATION PROCEDURE Page 4332 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 12520 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 12715 Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). Locations Engine Page 6700 Abbreviations And Meanings Part 22 Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Page 4240 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Locations Oxygen Sensor: Locations Engine, Right Side Page 9794 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 9283 6. Reach up behind the wheelhouse panel and pass the end of the radio antenna cable assembly through the cowl opening (1). 7. Install the antenna cable grommet assembly to the cowl opening. 8. Install the wheelhouse panel. 9. Install the radio antenna cable (2) to the radio extension cable. 10. Close the I/P compartment. Page 1716 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 3600 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. 2. Install the APP sensor retaining fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Recall 05V198000: Flasher Module Replacement Turn Signal Flasher: Recalls Recall 05V198000: Flasher Module Replacement MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2004 Chevrolet/Trailblazer 2003-2004 GMC/Envoy 2003-2004 Isuzu/Ascender 2003-2004 Oldsmobile/Bravada 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V198000 RECALL DATE: April 29, 2005 COMPONENT: Exterior Lighting: Turn Signal POTENTIAL NUMBER OF UNITS AFFECTED: 286478 SUMMARY: On certain trucks and sport utility vehicles, the driver wishing to signal a turn by moving the directional signal lever, (up or down) may cause the front marker/turn lights and rear turn lights to flash in a manner similar to hazard warning, rather than flashing on the desired side only. CONSEQUENCE: The driver may not be able to clearly signal their intentions to turn, change travel lanes, or potentially warn others of an impaired vehicle operating condition increasing the risk of a crash. REMEDY: Dealers will replace the suspect flasher modules with a new flasher module designed with sealed relays and more durable contact material inside of the relays. The recall is expected to begin during August 2005. owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727, Buick at 1-866-608-8080, and Oldsmobile at 1-800-630-6537. NOTES: GM recall No. 05044. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Page 2043 10. Remove the power steering hose assembly bracket retaining bolt at the wheel well. 11. Disconnect the power steering hose assembly bracket from the wheel well. 12. Remove the power steering hose assembly to frame brackets retaining bolts. 13. Remove the power steering hose assembly to front crossmember bracket mounting bolt. 14. Remove the power steering pressure hose (1) and power steering cooler hose (2) from the power steering pump. 15. Remove the power steering hose assembly from the vehicle. Installation Procedure 1. Install the power steering hose assembly to the vehicle. 2. Install the power steering cooler hose (2) the the power steering pump. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering pressure hose (1) to the power steering pump. Specifications Compressor/Pump: Specifications Air Spring Compressor to Frame Mounting Bolts 18 ft. lbs. Bracket Replacement - Console Floor Console: Service and Repair Bracket Replacement - Console Floor Bracket Replacement - Console Floor Removal Procedure 1. Block the wheels to prevent the vehicle from moving. 2. Remove the floor shift control knob. 3. Remove the center console. Console Replacement 4. Disconnect the automatic transmission range selector cable. 5. Disconnect the electrical connector from the automatic transmission shift interlock solenoid. 6. Disconnect the electrical connector from the park brake. 7. Remove the console bracket from the vehicle, by removing the retaining nuts (1) from the center instrument panel (IP) bracket. 8. Remove the forward retaining screw, if equipped. 9. Remove the remaining fasteners from the console bracket. 10. Remove the console bracket from the vehicle. 11. Remove the floor shift control. Installation Procedure 1. Install the floor shift control. 2. Install the console bracket to the vehicle. 3. Loosely install all the fasteners that retain the console bracket to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the retaining nuts (1) to the center IP bracket. Tighten nuts to 10 N.m (88 lb in). 5. Install the remaining fasteners that retain the console bracket to the vehicle. Tighten the nuts to 25 N.m (18 lb ft). 6. Connect the electrical connector to the park brake. 7. Connect the electrical connector to the automatic transmission shift interlock solenoid. 8. Connect the automatic transmission range selector cable. 9. Install the center console. Console Replacement 10. Install the floor shift control knob. 11. Remove the wheel blocks from the vehicle. Page 11495 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 12498 Page 2546 6. Align the installation arbor (1) onto the top of the cylinder bore sleeve (117). 7. Align the pusher block (2) of cylinder bore sleeve installer EN 45680-403 into the groove of fixture EN 45680-401(1). Note: Do not use any air powered or electric tools to rotate the threaded shaft of the fixture EN 45680-401/cylinder bore sleeve installer EN 45680403 assembly or damage to the cylinder bore sleeve will occur. Page 6112 Part 2 of 2 Page 7849 5. Remove the rear axle support. 6. Install the wheelhouse panel. 7. Install the tire and wheel. 8. Lower the vehicle. Rear Axle Lower Control Arm Replacement Rear Axle Lower Control Arm Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Raise and support the rear axle at the designed D - height. 3. If equipped with air suspension, Repressurize the air suspension system. 4. Remove the rear axle lower control arm to the axle mounting nut and bolt. 5. Remove the rear axle lower control arm to the frame mounting nut and bolt. 6. Remove the lower control arm. Page 10543 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 11175 3. Using the line from the china marker (4) as a guide and starting at the sill plate, install the seal along the rear rocker panel with seal bulb (2) toward the door. Flatten the bulb and align it to the china marker line pressing lightly. 4. Close the door and check for the gasket pushing out between the door and the body. 5. If the gasket was pushing out, realign the gasket in that area. 6. Trim the gasket so that it does not extend higher than the rocker panel (5) as necessary. 7. When the gasket is located, open the door and firmly press the gasket into place. A roller tool may be helpful in seating the gasket. 8. Check the door latch for proper operation: 8.1. Open the rear door. 8.2. Open the rear side closure. 8.3. Listen for two audible clicks while rotating the fork bolt from the full open to the fully latched position. 9. If two distinct audible clicks are NOT heard: Page 6886 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 120 Page 8412 Registered And Non-Registered Trademarks Part 6 Page 457 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 1477 Crankshaft Position (CKP) Sensor Page 4610 Fuel Injector 5 Page 8597 Evaporator Core: Service and Repair Evaporator Core - Auxiliary EVAPORATOR CORE REPLACEMENT - AUXILIARY TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the heater core-auxiliary. 2. Remove the inverted torx studs from the evaporator block-auxiliary. 3. Remove the backing plate (1) from the evaporator core. 4. Remove the screws from the blower motor control processor-auxiliary. 5. Remove the blower motor control processor-auxiliary. 6. Remove the screws from the HVAC module-auxiliary case sump (2). 7. Remove the HVAC module-auxiliary case sump (2). Page 9921 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 8396 Abbreviations And Meanings Part 16 Page 10042 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 84 Registered And Non-Registered Trademarks Part 3 Recall 04V046000: Erratic Wiper Operation Wiper Control Module: All Technical Service Bulletins Recall 04V046000: Erratic Wiper Operation DEFECT: The windshield wipers on these sport utility vehicles may fail to turn on, unexpectedly stop working, fail to turn off/on by themselves (moisture sensitive wiper system), or the washer pump may operate continuously because water can enter the wiper module and either cause a short circuit or corrosion of components within the module. Driver visibility could be reduced, which could result in a crash. REMEDY: Dealers will cover the windshield wiper module vent hole with a patch. Also, the wiper motor, circuit board, and electrical connector will be inspected for signs of water intrusion and/or corrosion and be replaced as required. The manufacturer has reported that owner notification is expected to begin during the third quarter of 2004. Owners may contact Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Oldsmobile at 1-800-630-6537. Page 3783 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic converter. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Page 10834 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 4924 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Page 13098 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 5841 Seals and Gaskets: Service and Repair Drive Pinion Flange/Yoke and/or Oil Seal Replacement Drive Pinion Flange/Yoke and/or Oil Seal Replacement Tools Required ^ J8614-01 Flange and Pulley Holding Tool ^ J33782 Pinion Oil Seal Installer ^ J38694 Extension Housing Oil Pump/Seal Installer Removal Procedure Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the rear brake calipers. 4. Remove the brake rotors. 5. Remove the propeller shaft. 6. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion oil seal ^ The differential case bearings ^ The axle bearings ^ The axle seals 7. Place an alignment mark between the pinion and the pinion yoke. Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 6637 Page 13956 Abbreviations And Meanings Part 26 Page 10611 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 3621 Crankshaft Position (CKP) Sensor Page 11153 An initial supply of weatherstrips required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of February 6, 2006, and will be approximately 10% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Important: It is estimated that less than 10% of involved vehicles will require lock replacement. Please order parts accordingly. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to the recall condition are to be submitted to dealers by February 28, 2007. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Claim Information Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 1101 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. Installation Procedure 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. Important: When replacing the passenger door module, the set up procedure must be performed. 4. If replacing the passenger door module, program the passenger door module. Refer to Service Programming System (SPS) (Remote Procedure) Service Programming System (SPS) (Pass-Thru Procedure) Service Programming System (SPS) (Off Board Remote Procedure) Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 7367 Application Table Part 2 Page 5081 Disclaimer Page 13781 Turn Signal/Mutifunction Switch C2 Service and Repair Video Cassette Player / Recorder: Service and Repair VIDEO PLAYER BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Remove the video display assembly. 2. Remove the two rear overhead console carrier screws (1). 3. Remove the front bracket retaining bolts. 4. Carefully pull down on the rearward edge of the headliner in order to expose the rear bracket retaining bolt. Page 230 Page 1275 Low Pressure Sensor / Switch: Description and Operation HVAC System - Automatic HVAC SYSTEM - AUTOMATIC A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 12 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 124 kPa (18 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275 kPa (40 psi). This enables the A/C compressor to turn back ON. Page 7997 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Step 1 - 4 Wheel Bearings Diagnosis Step 5 - 7 Service and Repair Ring Gear: Service and Repair Drive Pinion and Ring Gear Replacement Tools Required ^ J8614-01 Flange and Pulley Holding Tool ^ J22536 Pinion Driver ^ J38694 Extension Housing Oil Pump/Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake calipers. 4. Remove the brake rotors. 5. Remove the axle shafts. 6. Remove the differential assembly. 7. Remove the drive pinion yoke and the oil seal. 8. Install the J22536 as shown. Ensure that the J22536 is firmly seated on the pinion. 9. Drive the pinion out using the J22536 and a hammer. Strike the J22536 slowly. Do not let the pinion fall out of the rear axle housing. 10. Remove the collapsible spacer from the pinion. Discard the spacer. 11. Remove the pinion bearings and the cups. 12. Remove the left-hand threaded ring gear bolts. Discard the bolts. 13. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Installation Procedure Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Page 938 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 5748 5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring retaining bolt. 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. Page 6844 Page 8490 Control Assembly: Locations Instrument Panel, Center (w/Manual - HVAC System) Page 632 Mirror Connector, Front Passenger Door Module (FPDM) - C3 Part 1 Page 6882 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 3536 7. Install the rear electrical center cover. 8. If replacing the BCM on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 9. If replacing the BCM on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 10. Connect the negative battery cable. 11. If installing a replacement BCM, program the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Body Wiring Harness Extension Replacement - BCM BODY WIRING HARNESS EXTENSION REPLACEMENT - BCM REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the body wiring harness extension on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the body wiring harness extension on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. Page 12243 Liftgate Module (LGM) C2 (Except XUV) Page 6251 6. Remove the front brake pads from the mounting bracket. 7. Inspect the brake hardware. 8. Remove the brake pad retaining clips from the mounting bracket. 9. Remove the brake caliper mounting bracket retaining bolts. Specifications Valve Seat: Specifications Valve Seat Runout - Maximum 0.002 inch Valve Face Runout - Maximum 0.0015 inch Page 630 Front Passenger Door Module (FPDM) - C2 Part 1 Page 6805 Abbreviations And Meanings Part 9 Page 10182 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 8208 HVAC Module-Auxiliary (Body Type VIN 6) Page 7384 Fuse Block: Service and Repair Rear Electrical Center or Junction Block Replacement REAR ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a cargo position. 4. Remove the rear electrical center cover. 5. Remove the battery feed terminal nut (2) from the junction block. 6. Remove the body control module (BCM) from the rear electrical center. 7. Fully loosen the 3 bolts (1) that retain the junction block to the electrical connectors. Page 10197 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 6356 Notice: Refer to Fastener Notice in Service Precautions. 5. Install the rear brake caliper on the mounting bracket. ^ Tighten the brake caliper mounting bolts to 31 Nm (23 ft. lbs.). 6. Install the NEW metal (copper) gaskets on the brake hose bolt. 7. Remove the plug from the brake hose end. 8. Install the brake hose bolt on the rear brake caliper. ^ Tighten the brake hose bolt to 44 Nm (33 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting Page 2853 Page 194 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 11005 Cowl Moulding / Trim: By Symptom Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Page 10125 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 1172 Page 6742 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Page 85 Registered And Non-Registered Trademarks Part 4 Page 12918 Abbreviations And Meanings Part 7 Locations Park Neutral Position (PNP) Switch OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 8261 Air Duct: Service and Repair Defroster Duct DEFROSTER DUCT REPLACEMENT - WINDSHIELD REMOVAL PROCEDURE 1. Remove the I/P trim pad. 2. Remove the side window defroster duct (3) retaining screw (4). 3. Remove the passenger side window defroster duct. 4. Remove the retaining screw (1) from the driver side window defroster duct (4). 5. Remove the driver side window defroster duct. Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 6.6L (7.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Page 3488 Abbreviations And Meanings Part 5 Page 12855 Registered And Non-Registered Trademarks Part 6 Page 10709 4. Install the protective cover to the module. 5. Position the right rear seat bottom to a passenger position. 6. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 7. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 8. Use the ID information menu on the scan tool to access the new station ID (STID) and the electronic serial number (ESN) from the new VCIM. 9. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center and perform the following procedure: 9.1. Tell the advisor that this vehicle has received a new VCIM. 9.2. Ask the advisor to add the new STID and the ESN to update the customer's account. 9.3. Follow any additional instructions from the OnStar(R) advisor. 9.4. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Page 1787 Outside Moisture Sensor Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake Pressure Modulator Bleeder Valves 80 inch lbs. EHCU to Bracket 7 ft. lbs. EHCU Bracket Mounting Bolts 18 ft. lbs. Description and Operation Air Cleaner Restriction Indicator: Description and Operation The air cleaner restriction indicator is located on the intake duct between the air cleaner assembly and the throttle body. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Page 10785 Passlock Sensor OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 1443 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 2 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must reinstall the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. 2. Install the heated oxygen sensor (2) using a J 39194-B. Page 7094 C203 Page 11840 Abbreviations And Meanings Part 25 Page 577 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 4775 Throttle Body: Description and Operation THROTTLE BODY ASSEMBLY The throttle body for the TAC system is similar to a conventional throttle body with several exceptions. One exception being the use of a motor to control the throttle position instead of a mechanical cable. Another exception is the throttle position (TP) sensor. The TP sensor is mounted in the throttle body assembly. The TP sensor is 2 individual TP sensors within the throttle body assembly. Two separate signal, low reference, and 5-volt reference circuits are used to connect the TP sensors and the PCM. TP sensor 2 signal voltage increases as the throttle opens. TP sensor 1 signal voltage decreases as the throttle opens. Page 459 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 3112 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Page 954 Powertrain Control Module (PCM) C3 Part 3 Page 7642 11. Start the engine. Allow the engine to idle. 12. Turn off the engine. 13. Verify the fluid level. Repeat steps 11-13 until the fluid stabilizes. Important: Do not turn steering wheel to lock. 14. Start the engine. Allow the engine to idle. 15. Turn the steering wheel 180 - 360 degrees in both directions 5 times. 16. Switch the ignition off. Notice: When adding fluid or making a complete fluid change, always use the proper power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks. 17. Verify the fluid level. 18. Remove the pump reservoir cap. 19. Attach the J43485 to the J35555 or equivalent. 20. Place the J43485 on or in the pump reservoir filler neck. 21. Apply a vacuum of 68 kPa (20 in Hg) maximum. 22. Wait 5 minutes. 23. Remove the J43485 and the J35555. 24. Verify the fluid level. Page 9631 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 6638 Page 8888 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Steering Column Accident Damage Inspection ^ Vehicles involved in accidents involving the following conditions may also have a damaged or misaligned steering column: Frame damage - Major body or sheet metal damage - Where the steering column has been impacted - Where supplemental inflatable restraint systems deployed ^ Inspect the capsules on the steering column bracket assembly. All capsules must be securely seated in the bracket slots and inspected for any loose conditions when pushed or pulled by hand. ^ Observe how the bracket is attached to the jacket assembly. If the capsules are not securely seated and the bracket is bolted to the jacket assembly, replace only the bracket. - If the capsules are not securely seated and the bracket is welded to the jacket assembly, replace only the jacket assembly. - inspect for jacket assembly collapse by measuring the distance from the lower edge of the upper jacket to a defined point on the lower jacket. Replace the jacket assembly if the measured dimensions are not within specifications. ^ Inspect for tab (1) breakage on the bearing and adapter assembly. Procedures Power Seat Switch: Procedures Lumbar Switch Replacement - Front LUMBAR SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the switch bezel assembly from the seat. 2. Remove the power seat switch. 3. Release the tabs that retain the lumbar switch to the switch bezel assembly. 4. Disconnect the electrical connector from the lumbar switch. 5. Remove the lumbar switch from the switch bezel assembly. INSTALLATION PROCEDURE 1. Connect the electrical connector to the lumbar switch. 2. Install the lumbar switch to the switch bezel assembly, verifying that the retaining tabs are fully seated. 3. Install the power seat switch. 4. Install the switch bezel assembly to the seat. Seat Switch Bezel Replacement SEAT SWITCH BEZEL REPLACEMENT REMOVAL PROCEDURE Page 55 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 2181 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 4. Install the LF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Page 9670 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 843 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 11177 Page 6827 Registered And Non-Registered Trademarks Part 5 Page 11639 5. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 6. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Page 9354 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 8999 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Access IP module connector through glove box. 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 4997 Disclaimer Page 11892 Tighten the screws to 0.75 N.m (6 lb in). 5. Install the lock to the door. 6. Install the water deflector. 7. Install the door trim panel. Page 3470 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 3294 5. Install the HVAC module-auxiliary. Page 887 Registered And Non-Registered Trademarks Part 6 Page 4842 Camshaft Position (CMP) Sensor Page 205 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 13913 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 8034 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Page 4259 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Assembly Replacement Blower Motor Resistor: Service and Repair Assembly Replacement BLOWER MOTOR RESISTOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the right closeout/insulator panel. 2. Disconnect the blower motor resistor electrical connector (3). 3. Remove the blower motor resistor mounting screws (2). 4. Remove the blower motor resistor (1). INSTALLATION PROCEDURE 1. Install the blower motor resistor (1). 2. Install the blower motor resistor mounting screws (2). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to .....1.9 N.m (17 lb in). 3. Connect the blower motor resistor electrical connector (3). 4. Install the right closeout/insulator panel. Page 408 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 11240 9. Apply sealers and refinish as necessary. 10. Install all of the related panels and components. Page 10163 Instruments - Erratic Speedometer Operation Ground Strap: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 12137 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 10193 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 13348 Speedometer Head: Description and Operation SPEEDOMETER The IPC displays the vehicle speed based on the information from the PCM. The PCM converts the data from the vehicle speed sensor to a 4000 pulses/mile signal. The IPC uses the vehicle speed signal circuit (4000 pulses/mile) from the PCM in order to calculate the vehicle speed. If the IPC detects a malfunction in the vehicle speed signal circuit, the IPC uses the class 2 message from the PCM indicating the vehicle speed. OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Page 2257 Application Table Part 3 Location View Service and Repair Blower Motor Relay: Service and Repair BLOWER MOTOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover of the under hood fuse block. 2. Remove the blower motor relay (1) from the under hood fuse block (2). INSTALLATION PROCEDURE 1. Install the blower motor relay (1) to the under hood fuse block. 2. Install the cover of the under hood fuse block. Specifications Oil Pressure Sensor: Specifications Oil Pressure Sensor 15 ft. lbs. A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. A/T - 4L60-E, TCC Shudder/Water in Transmission Automatic Transmission Dipstick - Dipstick Tube: Customer Interest A/T - 4L60-E, TCC Shudder/Water in Transmission Bulletin No.: 05-07-30-031 Date: November 11, 2005 TECHNICAL Subject: 4L60-E Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal) Models: 2004-2005 Buick Rainier 2003-2005 Chevrolet TrailBlazer Models 2003-2005 GMC Envoy Models 2003-2004 Oldsmobile Bravada 2005 Saab 9-7X with 4.2L In-Line 6 Cylinder Engine (VIN S - RPO LL8) Condition Some customers may comment on a shudder condition at approximately 64-80 km/h (40-50 mph) when the TCC engages. Cause This condition may be caused by water in the automatic transmission fluid (ATF). Water may enter the transmission by dripping from the cowl area onto the handle of the transmission fluid level indicator. Indications of water in the ATF may include: ^ Visible rust on the transmission fluid level indicator. ^ Visible water in the oil pan. ^ A milky white substance inside the pan area. ^ Spacer plate gaskets that appear to be glued to the spacer plate, valve body or case. ^ Rust on internal transmission iron/steel components. Important: For vehicles suspected of having a leaking transmission oil cooler that would cause contamination of the transmission fluid with coolant, the following check should be performed before deciding to replace the radiator. ^ Remove the surge tank cap and examine the coolant for signs of contamination with transmission fluid (the coolant will have a milky, not clear appearance). ^ If the coolant has a normal, clear appearance, the radiator should not be replaced. The cooler can also be tested by following the Coolant System Leak Test procedure in the SI Document. Do NOT replace a radiator without verifying that the transmission oil cooler is leaking. Correction First, repair the transmission and second, replace the transmission fill tube, seal and level indicator to prevent repeat water contamination of the ATF. Transmission Repair 1. Remove the transmission. Refer to the appropriate SI procedure. 2. Disassemble and inspect the transmission. Refer to Unit Repair Automatic Transmission 4L60-E/4L65-E. Important: Page 4221 Page 10280 Speaker - LR Door Page 8426 Front Auxiliary Blower Motor Switch (w/Automatic HVAC System / Body Type VIN 6) Page 3176 33. Install the new hose, # 1003 (L6 engine) or # 1004 (V8 engine) onto the auxiliary heater pump inlet port. Connect the other quick connect end to the engine. Page 1050 4. Remove the three push-in retainers that attach the air inlet grille (leaf screen) to the plenum sheet metal. 5. Lower the hood to the secondary latch. 6. Using a suitable marker or masking tape, mark the location of both wiper blades on the windshield. 7. Remove the covers from the nuts that attach the wiper arms. 8. Remove the nuts from the wiper arms. Important If the rocking action in the next step fails to loosen the wiper arm, it may be necessary to use a standard top-post battery cable terminal puller to remove the wiper arm. 9. Rock the wiper arms back and forth to loosen and remove them from the wiper transmission shaft. 10. Remove the antenna mast. 11. Remove the 10 mm hex head nut that attaches the left and right ends of the air inlet grille to the plenum sheet metal. 12. Remove the air inlet grille and reposition it up to the windshield. It is not necessary to disconnect the washer hose. 13. Remove the two 10 mm hex head bolts that attach the wiper module to the plenum sheet metal. 14. Disconnect the electrical connector. 15. Remove the wiper module and place on a suitable work surface. Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 4849 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE 1. Install the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 881 Abbreviations And Meanings Part 26 Page 2285 8. Release the tabs that retain the junction block to the block base. 9. Remove the junction block from the block base. 10. Disconnect the instrument panel harness connector (1) from the junction block. 11. Disconnect the mobile telephone harness connector (1) from the junction block. Locations Cabin Temperature Sensor / Switch: Locations Instrument Panel Carrier - Right Side Instrument Panel Carrier - Center Section Page 1844 Steps 14-15 Page 2887 Liftgate Module (LGM) Power Trunk / Liftgate Control Module: Diagrams Liftgate Module (LGM) Liftgate Module (LGM) C1 (Except XUV) A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Page 873 Abbreviations And Meanings Part 18 Page 2279 Location View Service Precautions Vehicle Lifting: Service Precautions CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Page 1723 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 445 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 5003 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Slde Page 12122 Door Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 6712 Generator Page 456 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 1235 3. Remove the air temperature sensor. 4. Disconnect the electrical connector (2) from the upper air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the upper air temperature sensor (1) to the air duct (2). 2. Connect the electrical connector (2) to the upper air temperature sensor (1). 3. Install the upper air temperature sensor. 4. Install the HVAC control module. 5. Install the radio. Upper Right AIR TEMPERATURE SENSOR REPLACEMENT - UPPER RIGHT REMOVAL PROCEDURE 1. Remove the radio. Page 13273 Abbreviations And Meanings Part 11 Page 12722 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the windshield wiper arms. 2. Remove the inlet grille panel retaining nuts and push-pin retainers. 3. Remove the inlet grill panel pushpin retainers. 4. Disconnect the washer hose connection. 5. Remove the inlet grille panel from the vehicle, by pulling upwards in order to disengage the retaining clips. 6. Place the inlet grille panel on a clean, prepared surface. 7. Remove the rear hood seal from the inlet grille panel studs. 8. Remove the rear hood seal from the inlet grille panel. Installation Procedure 1. Position the rear hood seal to the inlet grille panel. 2. Install the rear hood seal to the inlet grille panel studs. 3. Position the inlet grille panel to the vehicle. 4. Press the inlet grille panel downward in order to seat the retaining clips. 5. Push downward on the inlet grille panel to seat the retaining clips. 6. Connect the washer hose connection. 7. install the pushpin retainers. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the inlet grille retaining nuts and push-pin retainers. Tighten the air inlet grille nuts to 4 N.m (35 lb in). 9. Install the windshield wiper arms. Page 1547 Impact Sensor: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. - Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. Page 12556 Abbreviations And Meanings Part 24 Multifunction, Turn Signal Switch Replacement Turn Signal Switch: Service and Repair Multifunction, Turn Signal Switch Replacement Multifunction, Turn Signal Switch Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the upper and lower trim covers. 3. Tilt the column to the CENTER position. 4. Disconnect the connectors from the turn signal and multifunction switch assembly. Remove 2 pan head tapping screws from the turn signal and multifunction switch assembly. 5. Remove the turn signal and multifunction switch assembly. Installation Procedure Important: The electrical contact on the turn signal and multifunction switch assembly must rest on the turn signal cancel cam assembly. 1. Install the turn signal and multifunction switch assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Secure by using 2 pan head tapping screws. - Tighten the screw on the top of the column to 3 Nm (27 inch lbs.). - Tighten the screw in the front to 7 Nm (62 inch lbs.). 3. Connect the connectors to the turn signal and multifunction switch assembly. 4. Install the upper and lower trim covers. 5. Enable the SIR system. Page 12256 Sunroof Harness With Headliner Removed Page 2954 Abbreviations And Meanings Part 26 Page 5303 Tip: It is necessary to remove the two A/C line (suction line / low side of muffler hose) retainers and reposition the A/C line to allow proper clearance for installation of the new transmission fluid fill tube. 5. Remove the A/C line at the oil level indicator tube bracket nut. 6. Remove the A/C bracket bolt from the engine lift hook. 7. Reposition the A/C line upward. 8. Install the new transmission filler tube, P/N 15000220, into position but NOT into the transmission at this time. 9. Raise the vehicle. 10. Remove the two bolts securing the transmission heat shield to the transmission. 11. Remove the transmission heat shield from the transmission. 12. Remove the old filler tube seal from the transmission case. 13. Install a new seal, P/N 1259475 into the transmission case. 14. Position the new transmission filler tube into the transmission seal. 15. Install the transmission heat shield to the transmission. 16. Install the two bolts securing the transmission heat shield to the transmission. Tighten Tighten the bolts to 17 N.m (13 lb ft). 17. Lower the vehicle. 18. Install the nut securing the filler tube to the stud. Tighten Page 2178 11. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 12. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 13. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 14. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 9 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 10394 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS DATA Battery Voltage: The scan tool displays the battery system voltage. INPUT Left Rear Door Jamb Switch: The scan tool displays the position of the left rear door. The scan tool displays On when the door is open. Right Rear Door Jamb Switch: The scan tool displays the position of the right rear door. The scan tool displays On when the door is open. Ignition 0: The scan tool displays the position of the ignition switch. The scan tool displays On when the ignition switch is in the Accessory, RUN or CRANK position. Ignition 1: The scan tool displays the position of the ignition switch. The scan tool displays On when the ignition switch is in the Run or Crank position. Ignition 3: The scan tool displays the position of the ignition switch. The scan tool displays On when the ignition switch is in the RUN position only. Ignition Accessory: The scan tool displays the position of the ignition switch. The scan tool displays On when the ignition switch is in the Accessory or RUN position only. Scan Tool Data List Scan Tool Output Controls Power Quarter Window Switch Replacement Power Window Switch: Service and Repair Power Quarter Window Switch Replacement POWER QUARTER WINDOW SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front overhead console. 2. Disconnect the electrical connector (1) from the quarter window switch. 3. Release the tabs retaining the quarter window switch to the overhead console. 4. Remove the quarter window switch from the overhead console. INSTALLATION PROCEDURE 1. Install the quarter window switch to the overhead console, ensuring the retaining tabs are fully seated. 2. Connect the electrical connector (1) to the quarter window switch. 3. Install the front overhead console. Page 4312 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data from the driver door module (DDM), Passenger door module (PDM) and the liftgate module (LGM) and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Page 1481 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. 1. Install the CKP sensor into the engine block. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 2566 Page 10893 Registered And Non-Registered Trademarks Part 3 Page 10617 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 3675 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 2 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must reinstall the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. 2. Install the heated oxygen sensor (2) using a J 39194-B. Page 199 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 2682 Engine Mount: Service and Repair Right Engine Mount and Bracket Replacement- Right Tools Required - J 41240 Fan Clutch Remover and Installer Removal Procedure 1. Disconnect the battery negative cable. 2. Using the J41240 to secure the water pump pulley. Loosen the cooling fan hub nut from the water pump shaft. 3. Remove the MAP sensor electrical connector and retainer (1). 4. Remove the MAP sensor (2). 5. Remove the right shock module, if frame engine mount is being removed. Page 6480 1. Install the park brake actuator lever housing to the backing plate. 2. Perform the following procedure before installing the backing plate bolts. 2.1. Remove all traces of the original adhesive patch. 2.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 2.3. Apply Threadlocker GM P/N 12345493 or Red LOCTITE #272 to the threads of the bolt. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the backing plate bolts. ^ Tighten the backing plate bolts to 95 Nm (71 ft. lbs.). 4. Install the park brake shoe. 5. Install the axle shaft. Page 7855 1. Install the steering gear crossmember. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the steering gear crossmember mounting bolts. Tighten the steering gear crossmember mounting bolts to 50 N.m (37 lb ft). 3. Install the rear lower control arm bracket to frame mounting bolts. Tighten the rear lower control arm bracket to frame mounting bolts to 240 N.m (177 lb ft). 4. Install the engine shield. 5. Install the engine shield mounting bolts. Tighten the engine shield mounting bolts to 25 N.m (18 lb ft). 6. Lower the vehicle. Page 11610 Console: Service and Repair Console Replacement Console Replacement Removal Procedure 1. Block the wheels to prevent the vehicle from moving. 2. Remove the rubber ash tray inserts and rubber mat from the console. 3. Remove the floor shift control knob. 4. Remove the center console shift lever bezel, Oldsmobile only. 5. Remove the console storage compartment. 6. Remove the center console retaining screws. 7. Adjust the parking brake to the full-up, or fully engaged position. 8. Release the 2 forward trim extensions ears attached to the lower IP-Oldsmobile only. 9. Slide the console rearward and raise the rear of the console in order to expose the electrical connectors. 10. Disconnect the electrical connectors as necessary. 11. Adjust the parking brake to approximately the halfway position. 12. Remove the center console from the vehicle. Installation Procedure 1. Position the center console to the vehicle. 2. Adjust the parking brake to the full-up, or fully engaged position. 3. Connect the electrical connectors as necessary. 4. Lower the rear of the console and slide the console forward into position. 5. Ensure that the 2 retaining ears on the front extensions of the console are fully engaged to the lower IP-Oldsmobile only. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the center console retaining screws. Tighten the screws to 2.5 N.m (22 lb in). 7. Install the console storage compartment. 8. Install the center console shift lever bezel 9. Install the floor shift control knob. 10. Install the rubber ash tray inserts and rubber mat to the console. Page 2032 1. Install new O-ring seals. 2. Install the compressor discharge hose (2) to the condenser (4). 3. Install the compressor discharge hose nut. NOTE: Refer to Fastener Notice in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Vehicle Damage Warnings Tighten Tighten the hose nut to .....28 N.m (21 lb ft). 4. Install the compressor hose to the connector through the driver wheel opening. 5. Install the nut. Tighten Tighten the nut to .....48 N.m (35 lb ft). 6. Install the compressor suction hose to the stud on the engine. 7. Install the nut. Tighten Tighten the nut to .....48 N.m (35 lb ft). 8. Install the compressor suction hose to the engine lift bracket. 9. Install the bolt. Tighten Tighten the bolt to .....48 N.m (35 lb ft). 10. Connect the compressor suction hose (1) to the accumulator. 11. Install the compressor suction hose nut to the accumulator. Tighten Tighten the nut to .....48 N.m (35 lb ft). 12. Install the sealing washers. Page 1242 Blower Motor Switch-Front Auxiliary Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ....................................... 334 - 375 kPa (48 - 54 PSI) Fuel Pressure Drop (After 1 minute) ............................................................................................................................................................. 34 kPa (5 PSI) Page 407 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 7264 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Interior - Revised Moonroof Sunshade Replacement Technical Service Bulletin # 02-08-110-006 Date: 021001 Interior - Revised Moonroof Sunshade Replacement File In Section: 08 - Body and Accessories Bulletin No.: 02-08-110-006 Date: October, 2002 SERVICE MANUAL UPDATE Subject: Revised Sunshade Replacement Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada This bulletin is being issued to revise the Sunshade Replacement procedure in the Interior Trim sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Removal Procedure 1. Remove the windshield garnish molding. Refer to Garnish Molding Replacement - Windshield Pillar. 2. Release the front assist handle from the headliner. Refer to Assist Handle Replacement. 3. Recline the bucket seat and release the upper portion of the center pillar trim panel. Refer to Garnish Molding Replacement - Center Pillar. 4. Open and rotate the sunshade parallel to the side window. 5. Insert a small tool into the bezel access hole (1). Page 175 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 588 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 6521 Installation Procedure 1. Install the gasket and the vacuum booster assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the vacuum booster mounting nuts on the vacuum booster. ^ Tighten the vacuum booster mounting nuts to 40 Nm (30 ft. lbs.). 3. Position the stop lamp switch (1) on the pushrod (2) and install on the brake pedal pin . 4. Install the pushrod retainer (3) to the brake pedal pin (4). The retainer will snap into place. 5. Install the left closeout/insulator panel. 6. Install the vacuum hose to the vacuum booster and to the engine. 7. Install the master cylinder. Page 6581 Page 11789 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 7910 11. Verify the pin can be removed and installed with ease to ensure the correct sensor installation. If the pin cannot be inserted with ease, loosen the sensor fasteners, adjust the sensor, and retighten the sensor fasteners until the pin can be removed and installed with ease. Notice: Failure to remove the air suspension auto level control sensor locating pin will cause damage to the air suspension auto level control sensor. 12. Remove the air spring level sensor locating pin. 13. Perform the sensor calibration for the right side. Raise or lower the vehicle so the left side D-height is 110 mm from the right side of the vehicle. 14. Raise the vehicle off the jackstands and remove the jackstands from under the vehicle. 15. Install the rear tires and wheels. 16. Lower the vehicle. 17. Install the air suspension fuse. 18. Turn the ignition key to the ON position to inflate the rear air springs. 19. After two minutes, turn the ignition key to the OFF position. 20. Recycle the ignition, if needed. 21. Verify and record the D-height. Page 9517 Locations Accelerator Entertainment System - DVD Monitor Display Inoperative Television / Monitor: Customer Interest Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Page 1345 Headlamp Switch C2 Page 11364 Do not use oxyacetylene welding equipment. MIG WELD ONLY. Weld the crack/four holes that were drilled through the inner panel using the appropriate welding technique. Prior to refinishing, refer to the GM4901M-D-2006 (English) or GM4901M-D-F2006 (French) GM Approved Refinish Materials booklet for recommended products. The GM Refinish Materials information is now on the GMGOODWRENCH WEB SITE ONLY. Printed books have been discontinued. Steps to the site are as follows: Go to www.gmgoodwrench.com. Click on GM Parts and Accessories link. Click on GM Technical Repair Information. Click on Paint Shop. Clean and prepare all of the welding surfaces. Return the surface to its original contour. Spot paint and clear the area around the hinges. Reinstall the liftgate. Replace the upper two bumpers and inspect the lower two bumpers. Replace as necessary. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9399 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Diagrams Trunk / Liftgate Motor: Diagrams Quarterglass Actuator - L Page 7655 2. Insert a screwdriver into the retaining clip tab (3). 3. Using the screwdriver, force the retaining clip tab (3) outward. 4. Slide the reservoir clip (4) away from the hydraulic pump assembly (1). 5. Repeat the above steps to remove the second reservoir clip (4). 6. Remove the reservoir (2) from the hydraulic pump housing (1). 7. Remove the O-ring seal from the neck of the reservoir (2) or inside the hydraulic pump housing (1). Discard the O-ring seal. Assembly Procedure 1. Lubricate the new O-ring seal with power steering fluid. 2. Install the new O-ring seal onto the neck of the reservoir (2). 3. Install the reservoir (2) onto the hydraulic pump assembly (1). Ensure the reservoir neck is completely engaged onto the hydraulic pump assembly (1). 4. Align the feet of the reservoir with the sides of the hydraulic pump housing. 5. Install the new reservoir retaining clips (4) (supplied with the pump). Ensure the retaining clip tabs (3) fully engage with the hydraulic pump housing (1). Page 12354 Memory Seat Module - Driver C2 Part 1 Page 1713 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 6941 Application Table Part 2 Page 12801 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 10027 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Door Window Channel Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Weatherstrip Run Channel Assembly Replacement - Rear (TrailBlazer EXT, Envoy XL) Window Weatherstrip Run Channel Assembly Replacement - Rear (TrailBlazer EXT, Envoy XL) Removal Procedure 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window regulator. 6. Carefully lower the glass into the door. 7. Remove the bolt (2) that retains the weatherstrip run channel to the door. 8. Pull the weatherstrip (1) loose from the window frame opening. 9. Release the clip retaining the quarter glass to the window opening by pulling forward on the run channel (4). Important: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip run channel assembly from the top of the door opening. Installation Procedure 1. Install the weatherstrip/run channel assembly to the door. 2. Install the quarter glass into the window opening by pressing the window channel (4) rearward until the retaining clip is fully installed. 3. Press the weatherstrip (1) into the window frame opening. 4. Position the tabs on the weatherstrip into the slots on the door. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten the bolt to 10 N.m (88 lb in). 6. Install the window glass into the run channel, slide up to the closed position, tape the window to the door frame. Communication Interface Module Replacement 1 Global Positioning System Module: Service and Repair Communication Interface Module Replacement 1 COMMUNICATION INTERFACE MODULE REPLACEMENT (TRAILBLAZER, ENVOY, BRAVADA) REMOVAL PROCEDURE 1. Position the right rear seat bottom to a cargo position. IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification and the 11-digit electronic serial number, are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 2. Remove the protective cover from the vehicle communication interface module (VCIM). 3. Remove the module from the upper bracket by releasing the retaining tab. Page 10355 Abbreviations And Meanings Part 8 Exhaust Camshaft Position Actuator Replacement Camshaft: Service and Repair Exhaust Camshaft Position Actuator Replacement Camshaft Position Exhaust Actuator Replacement Tools Required J 36660-A Torque Angle Meter - J 44217 Timing Chain Retention Tool Removal Procedure 1. Remove the camshaft cover. Refer to Camshaft Cover Replacement. 2. Rotate the engine until the word Delphi on the exhaust camshaft position actuator is lined up parallel with the cylinder head to cam cover mating surface. 3. Using the timing mark on the exhaust camshaft position actuator sprocket as a reference, make a mark on the timing chain link across from it. Page 12140 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 3392 Thermostat: Description and Operation Thermostat The thermostat is a coolant flow control component. Its purpose is to help regulate the operating temperature of the engine. It utilizes a temperature sensitive wax-pellet element. The element connects to a valve through a small piston. When the element is heated, it expands and exerts pressure against the small piston. This pressure forces the valve to open. As the element is cooled, it contracts. This contraction allows a spring to push the valve closed. When the coolant temperature is below the rated thermostat opening temperature, the thermostat valve remains closed. This prevents circulation of the coolant to the radiator and allows the engine to warm up. After the coolant temperature reaches the rated thermostat opening temperature, the thermostat valve will open. The coolant is then allowed to circulate through the thermostat to the radiator where the engine heat is dissipated to the atmosphere. The thermostat also provides a restriction in the cooling system, after it has opened. This restriction creates a pressure difference which prevents cavitation at the water pump and forces coolant to circulate through the engine block. Page 4093 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS HVAC System - Automatic Control Assembly: Service and Repair HVAC System - Automatic Auxiliary HVAC CONTROL MODULE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Using a flat bladed tool, carefully pry out on the top of the HVAC control-auxiliary. 2. Remove the HVAC control-auxiliary from the center console/seat. 3. Disconnect the electrical connector. 4. Remove the HVAC control-auxiliary. INSTALLATION PROCEDURE Page 8247 2. Disconnect the electrical connector from the mode actuator-auxiliary (1). 3. Remove the mode actuator-auxiliary (1) from the HVAC module-auxiliary. 4. Remove the retaining screws from the mode actuator-auxiliary. INSTALLATION PROCEDURE 1. Install the mode actuator (1) to the HVAC module-auxiliary. 2. Install the screws to the mode actuator-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector to the mode actuator-auxiliary (1). 4. Install the right rear quarter trim panel. 5. Calibrate the HVAC module actuators, See: Testing and Inspection/Programming and Relearning Mode Actuator - Console MODE ACTUATOR REPLACEMENT - CONSOLE REMOVAL PROCEDURE 1. Remove the floor console. 2. Rotate the console. 3. Remove the screw from the air outlet duct. 4. Remove the air outlet duct from the floor console. Page 10009 Page 11802 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 12375 Seat Lumbar Motors And Position Sensors Assembly - Driver Part 2 Locations Power Seat Page 3448 Page 8355 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 3610 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Page 5555 9. Remove the console. 10. Remove the drivers side front mat and carpet. 11. Remove the end of the range selector cable (1) from the floor control ball stud. 12. Remove the range selector cable (2) from the floor Shift control assembly. 13. Remove the tape and grommet on the Shift cable from the floor panel. 14. Remove the range selector cable (3) from the vehicle. Installation Procedure 1. Push the cable down through the floor panel and install the grommet (2). Inlet Radiator Hose: Service and Repair Inlet Body VIN Code 3 Radiator Hose Replacement - Inlet (Body Vin Code 3 / GMT 360) Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the coolant. 2. Reposition the inlet radiator hose clamp at the thermostat (1) using J 38185. 3. Remove the inlet radiator hose from the thermostat. 4. Raise the vehicle. Refer to Vehicle Lifting. See: Engine, Cooling and Exhaust/Service Precautions/Technician Safety Information/Vehicle Lifting Caution 5. Remove the lower radiator support shield, if equipped. 6. Reposition the inlet radiator hose clamp at the radiator using J 38185. 7. Remove the inlet radiator hose (1) from the radiator. Installation Procedure OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 858 Abbreviations And Meanings Part 3 Page 6973 Fuse Block - Underhood C2 Part 3 Page 65 Abbreviations And Meanings Part 10 Page 6276 9. Remove the rear brake pads. 10. Remove the brake pad retaining clips from the brake caliper mounting bracket. 11. Remove the retaining clip from the brake caliper. 12. Clean the brake caliper mounting bracket with denatured alcohol. 13. Using non-lubricated, filtered air, dry the brake caliper mounting bracket. Installation Procedure Important: When installing new brake pads, DO NOT reuse the old retaining clips for the brake pad. Use only NEW brake pad retaining clips. Page 12054 WA519F/12 - WA526F/72 OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 7382 7. Remove the junction block bracket retaining bolts (1) and remove the junction block bracket from the vehicle. INSTALLATION PROCEDURE 1. Position the junction block bracket and install the bolts (1). Tighten Tighten the junction block bracket bolts to 6 N.m (53 lb in). 2. Align the wiring harnesses and install the fuse relay center. 3. Install the fuse relay center bolts (3). Tighten Tighten the relay center bolts to 6 N.m (53 lb in). Page 7983 Pry the yoke away from the control arm to install the J 36607. 6. Remove the J 36607 and the shock module yoke to lower control arm retaining nut. 7. Remove the shock module from the shock tower and lower control arm. Installation Procedure 1. Install the shock module to the shock tower and lower control arm. 2. Install the shock module yoke to the lower control arm. 3. Lower the vehicle. 4. Install the shock module upper retaining nuts. Tighten the shock module upper retaining nuts to 45 Nm (33 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Raise the vehicle. Page 6646 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 11567 Remove the auxiliary seal and the auxiliary seal retainer. Clean the surface and fill the void with Medium Body Seam Sealer, P/N 12378500 (in Canada, P/N 10952233). Let stand for 60 minutes and touch up. Correction 2 Remove the auxiliary seal and the auxiliary seal retainer. Clean the area with a non oil base cleaner and fill the void with urethane sealer. Correction 3 Install four new plastic nuts in the "A" Pillar. The new nuts have a foam gasket that seals the perimeter when seated. Correction 4 Seat the push-in retainers fully at the bottom of the "A" pillar. Correction 5 Apply weatherstrip adhesive inside the primary seal retainer. Seal the retainer from the top of the dash to the bottom of the "A" pillar. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 13040 Compass: Adjustments COMPASS CALIBRATION AND VARIANCE PROCEDURE COMPASS CALIBRATION Before calibrating the compass, drive the vehicle to an area that is magnetically clean or free of large metallic objects. Verify there are no magnetized objects on the inside or outside of the vehicle close to the mirror. 1. Start the engine. 2. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or On/Off (w/UE1) depending on the type of mirror on the vehicle, until the letter "C" or "CAL" is displayed. 3. Drive the vehicle in circles at a speed of less than 8 km/h (5 mph) until the "C" or "CAL" is replaced by a proper vehicle heading. The calibration procedure is now complete. COMPASS MAGNETIC VARIATION ADJUSTMENT Magnetic variation adjustments are required when the compass displays a constant error in heading. Variation is the difference between magnetic north and true north due to geographical location. 1. Locate your current geographic location on the World Magnetic Variation Map. 2. Turn ON the ignition, with the engine OFF. 3. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or On/Off (w/UE1) depending on the type of mirror on the vehicle, until a zone number appears on the compass display. 4. Depress the switch for the compass to select the desired zone number. 5. Wait 5 seconds, the display will return to a compass heading. The variance procedure is now complete. Page 9639 Circuit/System Testing Component Testing Recall - Tail/Stop Lamp Inspection/Replacement Technical Service Bulletin # 04087 Date: 041116 Recall - Tail/Stop Lamp Inspection/Replacement Product Safety - Tail Lamps/Stop Lamps # 04087 - (Nov 16, 2004) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002-2004 Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, Oldsmobile Bravada, and 2004 Buick Rainier vehicles. In some of these vehicles, vibration and heat may cause the tail lamp/stop lamp bulb to loosen in its socket. If this occurs, the bulb may flicker and eventually become inoperative. The center high mounted stop lamp and turn signal functions are not affected and will operate as designed. The loss of one or both of the tail lamp/stop lamps could reduce the vehicle's visibility to following drivers and fail to warn others that the vehicle is braking and/or is stopped, which could lead to a vehicle crash. Correction Dealers are to inspect the tail lamp/stop lamp assemblies, and if necessary, replace them. Vehicles Involved Involved are certain 2002-2004 Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, Oldsmobile Bravada, and 2004 Buick Rainier vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US Page 13466 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Locations Accelerator Procedures Power Door Lock Switch: Procedures Switch Replacement - Door Lock and Side Window - Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle INSTALLATION PROCEDURE 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. 4. If replacing the driver door module, program the driver door module. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming and Personalization Description and Operation in Personalization. IMPORTANT: When replacing the driver door module, the set up procedure must be performed. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 6460 6. Remove the master cylinder reservoir from the master cylinder. Refer to Master Cylinder Reservoir Replacement. 7. Using a smooth, round-ended fool, depress the primary piston (2) and remove the piston retainer. 8. Remove the primary piston assembly from the cylinder bore. 9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated filtered air into the front outlet port in order the remove the secondary piston (1) with the primary (6) and secondary (5) seals, and the return spring. 10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston. Assembly Procedure Important: Do not use abrasives to clean the brake master cylinder bore. Page 4825 Ignition Coil 5 Page 10612 Page 9806 English Prevailing Torque Fastener Minimum Torque Development Part 1 Specifications Camshaft: Specifications Camshaft Cap Bolt 106 inch lbs. Camshaft Journal Diameter-All Intake and Exhaust #2 - #7 1.0612-1.0622 inch Journal Diameter - Exhaust #1 1.1794-1.1804 inch Camshaft Bore Diameter - All Intake and Exhaust #2 - #7 1.0638-1.0646 inch Camshaft Bore Diameter-Exhaust #1 1.1820-1.1828 inch Journal Clearance 0.0015-0.0033 inch Camshaft Endplay- Intake 0.0020-0.0079 inch Camshaft Endplay - Exhaust 0.0017-0.0084 inch Page 11799 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 1845 Steps 16-19 Page 13088 Page 8000 8. Lower the Vehicle. Page 12820 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 12711 Cowl Moulding / Trim: By Symptom Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Page 872 Abbreviations And Meanings Part 17 Page 10954 Front Bumper Cover / Fascia: By Symptom Technical Service Bulletin # 02-08-62-004B Date: 060602 Body - Front Bumper Fascia Panel Wavy Bulletin No.: 02-08-62-004B Date: June 02, 2006 TECHNICAL Subject: Front Fascia Wavy (Install Dual Lock) Models: 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer EXT LS Model 2006-2007 Chevrolet TrailBlazer LS, TrailBlazer SS Supercede: This bulletin is being revised to add model years and material allowance. Please discard Corporate Bulletin Number 02-08-62-004A (Section 08 - Body and Accessories). Condition Some customers may comment that the front fascia is wavy under the grille or under the front turn signals. Refer to the illustration above. Correction 1. Remove the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. 2. Remove the impact bar from the front fascia. 3. Remove the hot melt on the top of the impact bar. 4. Clean and scuff the impact bar with a scotch bright pad. 5. Apply a coating of GM Adhesion Promoter, P/N 12378462 (Canadian P/N 10953554), to the top surface of the impact bar and let dry. 6. Install 3M Dual Lock, P/N 06463, to the impact bar as shown in the illustration above. 7. Clean the fascia and apply the Adhesion Promoter to the fascia. 8. Install the impact bar to the fascia. Page 13164 The Timer is started and stopped using the DIC Select button. Holding the Select button for longer than 3 seconds while the Timer parameter is displayed will reset the Timer to 00:00:00. The Timer status and data value is retained in memory when the ignition is turned OFF. When the ignition is turned ON again, the Timer status and data value is resumed. The Timer maximum value is 99:59:59. When the maximum is reached, the Timer rolls over to 00:00:00 and continues to operate. FUEL INFORMATION DIC FUEL INFORMATION / RESET CAPABILITIES The available DIC Fuel Information and reset capabilities are as follows: Range - Can not be reset - Avg. Fuel Economy - Can be reset - Inst. Fuel Economy - Can not be reset - Engine Oil Life - Can be reset RANGE The range display is the estimated distance that the vehicle can travel under current fuel economy and fuel level conditions. This range is calculated from odometer information and class 2 messages. Fuel Range is capable of displaying values from 0 - 999 MI or km. Display appears as: RANGE: XXX MILES (English), RANGE: XXX km (Metric). If the range is less than 40 miles, RANGE: LOW will be displayed. AVERAGE FUEL ECONOMY The Average Fuel Economy (AFE) value is calculated by the cluster based on Trip Distance and Trip Fuel Used. Pressing the Select button for longer than 3 seconds while the Average Fuel Economy is displayed in the DIC will reset both the Trip Distance and Trip Fuel Used to 0.0. Average Fuel Economy is capable of displaying values from 0.0 to 99.9. Display appears as: AVG MPG XX.X (English), AVG L/100km XX.X XX (Metric), AVG km/l XX.X (Japanese). Trip Distance and Trip Fuel Used accumulated values are stored in memory when the ignition is turned OFF. INSTANTANEOUS FUEL ECONOMY Instantaneous Fuel Economy values are calculated by the cluster from odometer information and class 2 messages. The cluster calculates instantaneous fuel economy based on distance and fuel. Instantaneous fuel economy is capable of displaying values from 0.0 to 99.9. Display appears as INST MPG XX.X (English), INST L/100km XX.X (Metric), INST km/l XX.X (Japanese). Values for the Instantaneous fuel economy are not stored when the ignition is turned OFF. ENGINE OIL LIFE Engine Oil Life percentage values are based on class 2 messages to the IPC. The IPC requests this value when Engine Oil Life is selected on the DIC. Engine Oil Life is capable of displaying values from 0 to 100%. Pressing the Select button for longer than 5 seconds while Engine Oil Life is displayed on the DIC the value will reset to 100%. Display appears as ENGINE OIL LIFE: XXX%. FEATURE PROGRAMMING Refer to Personalization Description and Operation. DRIVER WARNINGS Page 235 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Steering Wheel - Removal Procedure Revision Steering Wheel: Technical Service Bulletins Steering Wheel - Removal Procedure Revision Bulletin No.: 03-02-35-006 Date: December 02, 2003 SERVICE MANUAL UPDATE Subject: Revised Steering Wheel Replacement Procedure Models: 2002 Cadillac Escalade, Escalade EXT 2001-2002 Chevrolet Silverado, Suburban, Tahoe 2002 Chevrolet Avalanche 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Express, SSR 2001-2002 GMC Sierra, Yukon, Yukon Denali, Yukon XL 2002-2003 GMC Envoy, Envoy XL 2003 GMC Savana 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 2003 Isuzu Ascender This bulletin is being issued to revise the Steering Wheel Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Service and Repair Catalyst Shield: Service and Repair Catalytic Converter Heat Shield Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the 5 bolts securing the heat shield to the floor panel studs. 3. Remove the heat shield from the vehicle. Installation Procedure 1. Place the catalytic converter heat shield onto the floor panel studs. NOTICE: Refer to Fastener Notice in Service Precautions. See: Powertrain Management/Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Secure the heat shield with the 5 bolts. Tighten the catalytic converter heat shield bolts to 7 Nm (62 inch lbs.). 3. Lower the vehicle. Page 1970 Drive Belt Falls Off Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. Page 4617 Fuel Injector: Testing and Inspection Fuel Injector Balance Test With special Tool SYSTEM DESCRIPTION Fuel Injector Balance Test Example (Typical) The scan tool is first used to energize the fuel pump relay. The fuel injector tester is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Steps 1-3 Page 11408 Disclaimer Page 9662 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 7302 Auxiliary Power Outlet: Service and Repair CIGAR LIGHTER HOUSING OR 12 VOLT ACCESSORY POWER RECEPTACLE REPLACEMENT TOOLS REQUIRED J 42059 Cigarette Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the 12 volt power supply or cigar lighter fuse. 2. Remove the socket by placing one side of the "T" portion of the tool J 42059 into the socket and into the square window tab. 3. Position the opposite "T" portion of the tool into the opposing square window tab. 4. Pull the socket straight out of the retaining ring. 5. Remove the tool from the socket. 6. Disconnect the electrical connector from the socket. Page 10978 3. Install the trailer/towing receptacle assembly to the bracket and rotate clockwise until fully seated. 4. Connect the trailer/towing receptacle electrical connector. 5. Install the rear fascia. 6. Install the spare tire carrier. Page 5156 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON(R) transmission fluid. Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Page 6847 Page 3166 47. Connect the electrical connector to the A/C low pressure switch. 48. Install the lower air cleaner housing/washer solvent tank assembly onto the mounting studs. 49. Install the two air cleaner housing/washer tank assembly retaining nuts to the mounting studs. 50. Connect the washer pump hoses. 51. Connect the washer solvent tank electrical and install wiring harness to the retaining clips. 52. Install the air inlet duct to the lower air cleaner housing/washer solvent tank assembly. 53. Install the air cleaner filter element and air outlet duct. 54. Install the air cleaner cover. 55. Install the tender rear upper brace. 56. Connect the negative battery cable. 57. Recharge the refrigerant system. 58. Fill the cooling system. 59. Inspect the cooling system for leaks. 60. Leak test the refrigerant fittings using J 39400-A. Parts Information Warranty Information Page 9724 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9153 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 2100 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 6934 Location View Page 8272 Air Register: Service and Repair Instrument Panel - Right AIR OUTLET REPLACEMENT - INSTRUMENT PANEL - RIGHT REMOVAL PROCEDURE 1. Remove the right instrument panel (IP) access cover. 2. Remove the screw (1) retaining the air outlet assembly to the IP. 3. Grasp and pull the outlet assembly rearward from the I/P. Page 8292 3. Disconnect the electrical connector (3) from the air temperature sensor-lower right (2). 4. Remove the air temperature sensor-lower right (2). INSTALLATION PROCEDURE 1. Install the air temperature sensor-lower right (2). 2. Connect the electrical connector (3) to the air temperature sensor-lower right (2). 3. Install the IP lower closeout panel. 4. Install the passenger side closeout panel. Upper Left AIR TEMPERATURE SENSOR REPLACEMENT - UPPER LEFT REMOVAL PROCEDURE 1. Remove the radio. 2. Remove the HVAC control module. Page 2202 Location View Page 9996 Page 443 Page 12480 Installation Procedure 1. Install the small loop (1) onto the rear seat cushion latch (2). 2. Install the strap through the opening in the seat pan. 3. Install the rear-seat cushion cover and the pad. 4. Install the rear seat cushion assembly to the vehicle. Page 10814 Body Control Module (BCM) Page 11886 Door Lock Actuator - RR Page 3044 Steps 1-3 Page 9689 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 11684 Scuff Plate: Service and Repair Door Sill Plate Replacement - Rear (TrailBlazer EXT, Envoy XL) Door Sill Plate Replacement - Rear (Trailblazer EXT, Envoy XL) Removal Procedure 1. Use a flat-bladed tool in order to release the 3 sill plate retaining tabs. 2. Remove the sill plate from the door frame. 3. Remove any retaining tabs that remain attached to the door frame. Installation Procedure 1. Ensure that all 3 retaining tabs are attached to the sill plate. 2. Align the retaining tabs to the door frame slots. 3. Push down on the sill plate, seating the retaining tabs to the door frame. Page 4287 Abbreviations And Meanings Part 21 Page 4528 Steps 14-15 Page 6169 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 12123 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 6510 11. Install the brake caliper and mounting bracket. 12. Install the tire and wheel. 13. Lower the vehicle. Refer to Vehicle Lifting. Page 5325 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Page 7458 C101 Part 2 Electrical Frontal Sensor Impact Sensor: Diagrams Electrical Frontal Sensor Electronic Frontal Sensor - Left Page 7686 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Access IP module connector through glove box. 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 254 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 8390 Abbreviations And Meanings Part 10 Page 1958 Accessory Drive Belt Routing Page 4226 Page 10830 Page 2696 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Low or No Oil Pressure The following can cause low or no oil pressure: * Low oil level-fill to the full mark on the oil level indicator. * Slow idle speed * Incorrect or malfunctioning oil pressure switch- replace the oil pressure switch. * Incorrect or malfunctioning oil pressure gage- replace the oil pressure gage. * Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature. - Install new oil if it is diluted. * The oil pump is worn or dirty-clean or replace the oil pump. * The oil filter is plugged-replace the oil filter. * The oil pickup screen is loose or plugged- replace the oil pickup screen. * A hole in the oil pickup tube-replace the oil pickup tube. * Excessive bearing clearance-replace the bearings. * Cracked, porous, or plugged oil galleries-repair or replace the engine block. * The gallery plugs are missing or improperly installed-install or repair as necessary. * The pressure regulator valve is stuck. Check the pressure regulator valve for sticking in the bore. - Check the bore for scoring and burrs. * The camshaft is worn or poorly machined- replace the camshaft. * Worn valve guides-repair as needed. Oil Pressure Testing Tools Required J 21867 Pressure Gauge and Hose - J 42907 Oil Pressure Tester Adapter If the vehicle has low oil pressure perform the following tests. 1. Check the oil level. 2. Raise the vehicle and remove the oil filter. 3. Assemble the plunger valve in the large hole of J42907 (1) base and the hose in the small hole of J42907 (1) base. Connect the J21867 (2) to the end of the hose. 4. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve itself. 5. Install J42907 (1) on the filter mounting pad. 6. Start the engine and check the overall oil pressure and the oil pressure switch. The engine should be at operating temperature before checking the oil pressure. The oil pressure should be approximately 85 kPa (12 psi) at 1200 rpm using 5W30 engine oil. 7. If adequate oil pressure is indicated, check the oil pressure switch. 8. If a low reading is indicated, press the valve on the tester base to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading while pressing the Page 13202 supported, only J2534. 1. BEFORE the original IPC is disconnected from the vehicle, record the odometer and engine hour values. 2. Replace the IPC with a replacement part obtained from the ESC. Refer to Instrument Cluster Replacement in SI. 3. Using the TIS2WEB SPS application, select either: J2534 Tech 2 or J2534 MDI, when available and build the vehicle. 4. Select: IPC Setup J2534. 5. After selecting IPC Setup J2534, the user will be prompted to: install the new controller. Ignore this prompt if the new IPC was already installed. This prompt is just to remind the user that this application is only for a new IPC. Important FOR 2003 FULLSIZE TRUCKS, UTILITIES AND H2, THE ENGINE MUST BE STARTED AND RUNNING PRIOR TO ENTERING THE MILEAGE AND ENGINE HOURS. After the odometer value is programmed, the engine must remain running for 6 minutes 15 seconds before the ignition can be turned off. Failure to do so will result in engine hours not being programmed and a new IPC will have to be ordered. 6. Enter the odometer and engine hour values, when applicable. By default the application will be set to miles. For metric units, click the button on the left next to: Kilometers. The IPC odometer and engine hour meter setup procedure is now complete. 7. The IPC calibration files can now be programmed into the IPC. Refer to SPS in SI. Disclaimer Page 12598 Power Door Lock Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the rear door ajar switches in the door lock assemblies as one method to activate the alarm. The body control module (BCM) monitors rear door ajar switches via a discrete input from each rear passenger door ajar switch, if the BCM receives a ground signal from a rear passenger door ajar switch when the CTD system is armed, the BCM activates the alarm. The CTD system uses the LH front door ajar switch as one method to activate the alarm. The driver door module (DDM) monitors the LH door ajar switch via a discreet input from the door ajar switch, if the DDM receives a ground signal from the LH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the RH front door ajar switch as one method to activate the alarm. The passenger door module (PDM) monitors the RH door ajar switch via a discreet input from the door ajar switch, if the PDM receives a ground signal from the RH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the rear compartment liftgate/liftglass ajar switchs as one method to activate the alarm. The liftgate module (LGM) monitors the liftgate and liftglass ajar switch via a discreet input from the ajar switch, if the LGM receives a ground signal from the liftgate or liftglass ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. Page 4136 Abbreviations And Meanings Part 22 Page 4292 Abbreviations And Meanings Part 26 Page 8385 Abbreviations And Meanings Part 5 Page 13016 Abbreviations And Meanings Part 17 Page 7504 C800 Part 1 Page 7267 Abbreviations And Meanings Part 3 A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: All Technical Service Bulletins A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Page 3735 Knock Sensor (KS) 2 Front Page 4117 Abbreviations And Meanings Part 3 Page 3026 Page 9557 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Procedures Seat Cushion: Procedures Seat Cushion Frame Replacement - Front SEAT CUSHION FRAME REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the 3 seat switch bezel mounting screws. 2. Remove the 4 nuts that secure the seat pan to the power seat adjuster frame. 3. Remove the clip from the front outboard seat pan stud , if equipped. Discard the clip. 4. Disconnect the black electrical connector (6) from the seat back harness. 5. Disconnect the black electrical connector (3) from the seat belt buckle. 6. Disconnect the gray lumbar electrical connector (5), if equipped. 7. Remove the SIR harness (2) from the harness clips (1, 4), and remove the SIR harness from the seat. 8. Remove the seat harness from the seat pan. 9. Remove the seat memory module, if equipped. 10. Remove the seat cushion assembly. 11. Remove the seat cushion cover and pad from the seat frame. 12. Remove the wiring harness and connector clips, if you are replacing the frame. INSTALLATION PROCEDURE 1. Install the wiring harness and connector clips, if you replaced the frame. 2. Install the seat memory module, if equipped. Page 13281 Abbreviations And Meanings Part 19 Locations Page 3936 Abbreviations And Meanings Part 23 Page 6181 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 10910 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data from the driver door module (DDM), Passenger door module (PDM) and the liftgate module (LGM) and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Page 13642 License Lamp - Right Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor (VSS) Page 12405 Seat Adjuster Switch - Passenger (w/Heat) Part 1 Interior - Front Floor Carpet Is Wet Carpet: Customer Interest Interior - Front Floor Carpet Is Wet TECHNICAL Bulletin No.: 03-08-57-004D Date: November 21, 2008 Subject: Front Floor Carpet Wet (Seal Top of "A" Pillar) Models: 2004-2007 Buick Rainier 2002-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2009 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 03-08-57-004C (Section 08 - Body and Accessories). Condition Some customers may comment that the front floor carpet is wet. Cause 1 Water may enter a hole in the seam sealer at the roof panel to upper "A" pillar post. In this case, the water enters the hole and leaks down the inside of the "A" pillar and ends up on the front floor. Refer to the illustration above. Cause 2 Water may enter the seam at the top of the "A" pillar. In this case, the water enters where the roof panel to upper "A" pillar meet and follows this seam under the windshield urethane. The water then drips onto the "A" pillar garnish molding and ends up on the floor. Refer to the illustration above. Cause 3 Specifications Wheel Hub: Specifications Wheel Hub and Bearing Mounting Bolts 77 ft. lbs. Wheel Hub Bolt 95 ft. lbs. Wheel Speed Sensor to the Wheel Hub and Bearing Mounting Bolt 13 ft. lbs. Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 3410 9. Loosen and remove the exhaust manifold bolts. 10. Remove the exhaust manifold. 11. Remove the exhaust manifold gasket. Installation Procedure 1. Install a new exhaust manifold gasket. 2. Install the exhaust manifold. Exhaust Manifold Bolt Torque Sequence NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 3. With threadlock GM P/N 12345493 (Canadian P/N10953488) on the manifold bolts, install the bolts onto the manifold. 3.1. Tighten the exhaust manifold bolts first pass in sequence to 20 Nm (15 ft. lbs.). 3.2. Tighten the exhaust manifold bolts second pass in sequence to 20 Nm (15 ft. lbs.). Page 2814 Abbreviations And Meanings Part 12 Page 9000 6. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 7. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Zone 6 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the RF door trim panel. Page 47 Conversion - English/Metric Part 2 Page 2583 6. Install J 41816-2 and J 41816-A to the balancer. Important: Do not pull on outer edge of the crankshaft balancer. 7. Remove the crankshaft balancer. 8. Remove the puller and the J 41816-A. 9. Remove the crankshaft balancer shim from the crankshaft snout. 10. Clean and inspect the crankshaft balancer. Installation Procedure Important: The crankshaft balancer does not have a key-way; so the crankshaft could turn when tightening, causing an improper torque. Make sure to follow the installation procedure to prevent damage. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Install a new crankshaft balancer shim. For 2003 and first design 2004 use GM P/N 12573950 over the crankshaft snout, against the crankshaft gear. For second design 2004 and after use GM P/N 12578073. Service replacement balances will come with the correct shim. 3. Using the EN-48034 install and seat the crankshaft balancer. 4. Remove the EN-48034. 5. Install J 44226-1 to hold the balancer from turning. Page 5589 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 11792 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 4835 Knock Sensor (KS) 2 Front Page 9140 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 6214 Abbreviations And Meanings Part 13 Page 6234 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 7491 C312 Part 2 Page 10307 Page 7349 Fuse Block - Underhood C1 Part 6 Fuse Block - Underhood C2 Page 7513 Application Table Part 3 Page 12632 Seat Adjuster Switch - Passenger (w/Heat) Part 2 Page 7521 8. Release the tabs that retain the junction block to the block base. 9. Remove the junction block from the block base. 10. Disconnect the instrument panel harness connector (1) from the junction block. 11. Disconnect the mobile telephone harness connector (1) from the junction block. Page 6832 3. Connect the positive battery cable to the starter solenoid and secure the cable with a nut (1). Tighten Tighten the positive cable nut to 9 N.m (80 lb in). 4. Install the left tire. 5. Connect the battery negative cable. Page 8362 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 827 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 13960 Registered And Non-Registered Trademarks Part 4 Page 3160 32. Install the new hose (1), # 1005 (L6 engine) or# 1006 (V8 engine) onto the coolant bypass valve at the location the above hose was removed. The other end of this hose will be installed on the auxiliary heater pump outlet port. Page 2934 Abbreviations And Meanings Part 6 Page 8861 Low Pressure Sensor / Switch: Locations Engine Compartment, Right Rear (w/Manual HVAC System) Engine Compartment, Right Rear (w/Automatic HVAC System) Page 2881 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 12926 Abbreviations And Meanings Part 15 Page 4685 On some 2004 model year Buick Rainier and GMC Envoy XUV; 2002-2004 model year Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles currently or previously registered in the corrosion areas shown above, the fuel tank modular reservoir assembly, which contains the fuel pump, may develop corrosion of the fuel feed/return pipes after an extended period of time. Severe corrosion may cause the formation of small perforations. These perforations may allow a small amount of fuel to accumulate in a recessed area outside of the fuel tank. If this were to occur, it would be accompanied by a fuel odor. If left uncorrected and the corrosion is allowed to progress, a fuel spray from the pipes may begin to occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to replace the fuel tank modular reservoir. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 30, 2008, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 30, 2008, must be submitted to the Service Contract provider. Vehicles Involved Page 9183 Abbreviations And Meanings Part 16 Page 1422 Manifold Absolute Pressure (MAP) Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 3. Press the retainer locking tabs inward, then pull the retainer (1) up to remove it. 4. Remove the MAP sensor (2). 5. Inspect the MAP sensor seal for damage, and replace as necessary. INSTALLATION PROCEDURE Page 12549 Abbreviations And Meanings Part 17 Page 7053 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 6647 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 6178 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 225 Page 12282 12. Apply and maintain upward pressure to the pivot arm while rotating the sunshade parallel to the side window. The sunshade arm should appear flush with the bezel. 13. Rotate and clip the sunshade to the inboard retainer. 14. Ensure the pivot arm retaining tabs are fully seated to the roof panel. 15. Install the front assist handle to the roof panel. Refer to Assist Handle Replacement. 16. Install the windshield garnish molding. Refer to Garnish Molding Replacement - Windshield Pillar. 17. Install the center pillar trim panel. Refer to Garnish Molding Replacement - Center Pillar. 18. Return the bucket seat to an upright position. Ignition System - MIL ON/Misfire DTC's In Wet Weather Cowl Moulding / Trim: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Instruments - Erratic Speedometer Operation Engine Control Module: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 3270 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. 2. Disconnect the negative battery terminal. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the Page 3438 Page 7924 Page 12754 7. Install the window regulator. 8. Install the water deflector. 9. Install the outer window belt sealing strip. 10. Install the inner window belt sealing strip. 11. Install the trim panel. Window Weatherstrip Run Channel Assembly Replacement - Rear (TrailBlazer, Envoy, Bravada) Window Weatherstrip Run Channel Assembly Replacement - Rear (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window. 6. Remove the bolt that retains the weatherstrip run channel to the door. 7. Pull the weatherstrip/run channel from the window frame opening. 8. carefully release the double sided tape attaching the molding to the outside of the door. 9. Carefully twist the weatherstrip run channel and pull up at the top of the door frame. Important: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip/run channel from the door. Installation Procedure 1. Install the weatherstrip/run channel to the door. 2. Press the weatherstrip/run channel into the window frame opening. 3. Position the tabs on the weatherstrip/run channel into the slots on the door. 4. Attach the molding to the outside of the door with double sided tape. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten the bolt to 10 N.m (88 lb in). 6. Install the window. 7. Install the water deflector. 8. Install the outer window belt sealing strip 9. Install the inner window belt sealing strip. 10. Install the trim panel. Page 1228 Ambient Air Temperature Sensor Locations Engine, Right Front Page 9982 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 11776 Page 6262 Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear brake hose bolt from the rear brake caliper. 4. Plug the opening of the brake hose in order to prevent excessive brake fluid loss and contamination. Important: Discard the metal (copper) gaskets. DO NOT reuse metal (copper) gaskets, replace them. 5. Remove the metal (copper) gaskets from the brake hose bolt. 6. Remove the rear brake caliper mounting bolts. Page 899 Door Control Module Diagram 2 Page 12527 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 3495 Abbreviations And Meanings Part 12 Page 4524 Steps 1-3 Page 3572 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 357 Page 12952 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 12400 Seat Adjuster Switch - Driver (w/o Memory) Part 1 Page 2618 1. Lubricate and fill the valve lash adjusters with engine oil. 2. Install the valve lash adjusters in their original locations. 3. Lubricate the valve rocker arm roller. 4. Install the valve rocker arms in their original locations. 5. Coat the camshaft journals with engine oil. 6. Install the camshafts to their original position Page 12927 Abbreviations And Meanings Part 16 Page 1700 Page 2987 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine oil pan drain plug and drain the engine oil. 3. Remove the engine protection shield mounting bolts. 4. Remove the engine protection shield. 5. Disconnect the electrical connector from the engine oil level sensor. 6. Remove the engine oil level sensor mounting bolt. 7. Remove the engine oil level sensor. Page 13953 Abbreviations And Meanings Part 23 Page 10804 Trailer Connector Page 9290 Alarm Module: Service and Repair THEFT DETERRENT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. CAUTION: SIR Caution 2. Remove the trim covers. 3. Remove the wire harness straps from the wire harness. 4. Disconnect the connector from the theft deterrent control module. 5. Remove the theft deterrent control module. INSTALLATION PROCEDURE 1. Install the theft deterrent control module. 2. Connect the connector from the theft deterrent control module. 3. Install new wire harness straps to the wire harness assembly. 4. Install the trim covers. 5. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Page 7977 Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation. Loosen the shock module yoke to lower control arm retaining nut. Remove the shock module yoke from the lower control arm using J 36607. Pry the yoke away from the control arm to install the J 36607. Remove the J 36607 and the shock module yoke to lower control arm retaining nut. Remove the shock module from the shock tower and lower control arm. Installation Procedure Page 9531 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 9786 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Read this procedure carefully and completely. 2. The BCM will not function properly if the Setup New BCM procedure is not performed. 3. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Front Stabilizer Bushing: Service and Repair Front Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise the and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft insulator clamp mounting bolts. 3. Remove the stabilizer shaft insulator clamp from the stabilizer shaft insulator. 4. Lower the stabilizer shaft and remove the stabilizer shaft insulator. Installation Procedure 1. Install the stabilizer shaft insulator to stabilizer shaft with slit facing the front of the vehicle. 2. Install the stabilizer shaft insulator clamp to the stabilizer shaft insulator. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the stabilizer shaft insulator clamp mounting bolts. Tighten the stabilizer shaft insulator clamp mounting bolts to 55 Nm (41 ft. lbs.). 4. Lower the vehicle. Page 12915 Abbreviations And Meanings Part 4 Page 6563 Page 9539 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 10878 Abbreviations And Meanings Part 14 Page 4757 Fuel Tank Unit: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 44402 Fuel Tank Sending Unit Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Use the J 44402 to remove the fuel sender assembly retaining ring. NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 3. Remove the fuel sender assembly and the seal. Discard the seal. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 4. Clean the fuel sender sealing surfaces. INSTALLATION PROCEDURE 1. Install the new seal on the fuel tank. CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 4158 Steps 1-5 Page 13245 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 7332 Fuse Block - Rear C1 Part 6 Fuse Block - Rear C2 Fuse Block - Rear C2 Part 1 Page 12281 7. Position the wire harness retaining clip between the headliner and the roof panel. 8. Position the index tabs on the wire harness retaining clip to the pivot arm and install the clip until fully seated. With the wire harness retaining clip installed, the sunshade should remain attached to the headliner. 9. Position the inboard retainer (1) to the roof panel. Notice: Refer to Fastener Notice in Cautions and Notices. 10. Install the inboard retaining screw. Tighten Tighten the screw to 1.2 N.m (10 lb in). 11. With the sunshade parallel to the windshield, index the pivot arm tab to the roof panel slot. Page 8922 Inflatable Restraint Sensing And Diagnostic Module: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Page 6540 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 8923 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 7597 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Page 6388 Engine Oil Level And Temperature Sensor Page 1921 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Page 7584 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Locations Electronic Components Page 7803 For vehicles repaired under warranty, use the table. Disclaimer Page 13430 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by November 30, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement~ they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Note: Locations Door Switch: Locations Door Jamb Switch, Miniwedge - LR A/C - Poor Rear Heater Performance Auxiliary Water Pump: Customer Interest A/C - Poor Rear Heater Performance Bulletin No.: 05-01-37-002A Date: November 01, 2005 TECHNICAL Subject: Poor Rear Heat Performance (Install Auxiliary Heater Pump) Models: 2003-2005 Chevrolet TrailBlazer EXT 2003-2005 GMC Envoy XL Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 05-01-37-002 (Section 01 - HVAC). Important: Implementation of this Service Bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on poor 2nd and/or 3rd row seating heater performance when the vehicle is at idle. Cause This condition may be due to lack of coolant circulation to the rear heater core. Correction Install auxiliary heater pump package, P/N 89024885 (L6 Engine RPO LL8) or P/N 89024886 (V8 Engine RPO LM4 or LH6). This pump will improve coolant flow to the rear heater core. Use the procedure listed below. 1. Recover the A/C refrigerant. 2. Drain the cooling system. 3. Disconnect the negative battery cable. 4. Remove the fender rear upper brace. 5. Remove the air cleaner cover. 6. Remove the air cleaner filter element and air outlet duct. 7. Remove the air inlet duct from the lower air cleaner housing/washer solvent tank assembly. 8. Disconnect the washer solvent tank electrical and remove wiring harness from the retaining clips. 9. Disconnect the washer pump hoses and plug the pump outlet ports to prevent loss of washer solvent. 10. Remove the two air cleaner housing/washer tank assembly retaining nuts from the mounting studs. 11. Lift the lower air cleaner housing/washer tank assembly off of the studs and remove the assembly. 12. On the A/C accumulator, disconnect the electrical connector from the low pressure switch. 13. Remove the compressor suction hose assembly from the accumulator. 14. Remove the nut retaining the accumulator to the evaporator. 15. Remove the coolant hoses from the coolant recovery reservoir. Page 8258 6. Install the headliner. 7. Install the right rear quarter trim. Page 11585 Disclaimer Page 9521 Page 9091 Inflatable Restraint Electronic Frontal Sensor Page 404 Page 12246 Endgate Module (EGM) C2 (XUV) Part 1 Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Page 5464 Seals and Gaskets: Service and Repair Filler Tube and Seal Replacement Filler Tube and Seal Replacement Removal Procedure 1. Remove the filler tube indicator. 2. Remove the nut (2) securing the filler tube to the exhaust manifold stud (1). 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Position a drain pan under the vehicle. 5. Remove the filler tube (1) and seal (2) from the vehicle. Installation Procedure Page 6803 Abbreviations And Meanings Part 7 Page 1204 Installation Procedure 1. Install the engine oil level sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine oil level sensor mounting bolt. ^ Tighten the engine oil level sensor mounting bolt to 10 Nm (89 inch lbs.). 3. Connect the electrical connector to the engine oil level sensor. 4. Install the engine protection shield. 5. Install the engine protection shield mounting bolts. ^ Tighten the engine protection shield mounting bolts to 25 Nm (18 ft. lbs.). Page 5293 Disclaimer A/C - Slow to Cool in Hot/Humid Conditions Fan Clutch: All Technical Service Bulletins A/C - Slow to Cool in Hot/Humid Conditions Bulletin No.: 04-01-38-019A Date: June 07, 2005 TECHNICAL Subject: Intermittent Slow to Cool HVAC Performance Concerns in High Ambient Temperatures and/or High Humidity Conditions After Start Up, Especially at Low Engine Speeds (Install New Engine Cooling Fan Clutch) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer Models 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005 Saab 9-7X Supercede: This bulletin is being revised to provide repair information for this customer concern. Please discard Corporate Bulletin Number 04-01-38-019 (Section 01 - HVAC). Condition Some customers may comment on slow to cool Air Conditioning (A/C) performance or high A/C outlet temperatures after start up or that the A/C system is not cooling sufficiently, especially in high ambient temperatures. This may be an intermittent condition and the performance of the Heating, Ventilation and Air Conditioning (HVAC) system may not meet customer expectations. Cause This condition may be caused by the response of the Electro-Viscous (EV) fan clutch and can be related to airflow across the condenser. This low A/C system performance can occur for longer periods of time if the vehicle is allowed to idle or is driven in low speed conditions. The response of the EV fan clutch will affect A/C system performance. As higher road speeds are attained, the increased airflow across the condenser will usually improve A/C system performance and the response of the EV fan clutch. This condition may be more evident after the vehicle has set for a period of time and can be difficult to duplicate. The condition may occur after the vehicle has set for as little as 10 minutes or as long as overnight. It is most prevalent intermittently during the first 15 minutes of operation. Correction Technicians are to replace the EV fan clutch with a new design part, P/N 15293048, on vehicles built before June 2005. Vehicles built in June 2005 may already have the updated EV fan clutch and it will not need to be replaced. For 2004 model year vehicles and older, update the Powertrain Control Module (PCM) with a software calibration that was developed to improve coolant temperature gauge readings. This new calibration will cause the PCM to command small amounts of additional fan engagement to better control engine coolant temperatures. Model year 2005 vehicles already have this calibration installed. Refer to Corporate Service Bulletin Number 04-06-02-005 for more information about this calibration. Proper diagnosis of any customer concern is essential. Refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure in SI to begin a diagnosis of any HVAC concerns. Refer to the Diagnostic Starting Point-Engine Cooling procedure in SI to begin a diagnosis of any engine cooling or engine cooling fan concerns. If an attempt is made to diagnose an HVAC system concern, all parameters must be measured. As an example, both the low and high side refrigerant pressure readings must be measured. If only the low side pressure readings were measured, it would appear that the A/C compressor is disengaging at a higher pressure than expected. If both the low and high side pressures were being measured, it would be noted that the A/C compressor is probably disengaging due to the maximum high side pressure cut out point being reached. This occurs to protect the HVAC system from damage. The updated PCM software calibration along with the updated EV fan clutch will improve this condition due to increased air flow across the condenser. The new EV fan clutch has an increased minimum operating fan speed and an improved response time. Additional engine cooling Page 3668 Exhaust Pipe Page 7030 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 10019 Page 3953 Body Control Module (BCM) C3 Part 2 Page 1779 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. 4. If replacing the passenger door module, program the passenger door module. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. IMPORTANT: When replacing the passenger door module, the set up procedure must be performed. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 8359 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Page 13753 Parts are currently available from GMSPO. Disclaimer Recall - Rear Side Door Latch Corrosion Technical Service Bulletin # 05077 Date: 060216 Recall - Rear Side Door Latch Corrosion Bulletin No.: 05077 Date: February 16, 2006 SAFETY Subject: 05077- REAR SIDE DOOR CLOSURE Models: 2002-2003 CHEVROLET TRAILBLAZER EXT 2002-2003 GMC ENVOY XL LOCATED IN CORROSION AREAS Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002-2003 Chevrolet TrailBlazer EXT and GMC Envoy XL vehicles that have ever been registered in corrosion areas. The rear side doors on these vehicles may not latch or may not unlatch properly due to corrosion caused by road splash, such as water and road salt. Depending on the location of the corrosion in the latch, the door may either be difficult to open from the inside or outside, or may bounce back when the door is swung shut from the outside. The driver information center may or may not indicate that the door is ajar. If the door is not latched properly and it goes unnoticed, it may open while the vehicle is in motion. If the occupant is unbelted, they may fall out of the vehicle and personal injury could occur. Correction Dealers are to install a seal to prevent water intrusion into the latch. The latch is also to be inspected and replaced, if necessary. Vehicles Involved Page 10033 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 1326 Turn Signal/Multifunction Swtich C4 Page 4615 Steps 1-4 Page 6249 5. Install the brake caliper mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the caliper mounting bracket bolts. ^ Tighten the caliper mounting bracket bolts to 150 Nm (110 ft. lbs.). 7. Install the rear brake pad hardware to the brake caliper mounting bracket. 8. Install the brake pads to the brake caliper mounting bracket. Power Steering Gear Replacement Steering Gear: Service and Repair Power Steering Gear Replacement Power Steering Gear Replacement Tools Required ^ J24319-B Steering Linkage and Tie Rod Puller ^ J44586 Power Steering Gear Oil Seal Remover/Installer Removal Procedure 1. Raise and support the vehicle. 2. Install a drain pan under the vehicle. 3. Remove the tires and wheels. 4. Remove outer tie rods retaining nuts. Notice: Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint. 5. Disconnect the outer tie rods from the steering knuckles using J24319-B. Page 12780 Page 851 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 9384 Abbreviations And Meanings Part 18 Page 13289 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 10363 Abbreviations And Meanings Part 16 OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Description and Operation Muffler: Description and Operation Muffler The exhaust muffler reduces the noise levels of the engine exhaust by the use of tuning tubes. The tuning tubes create channels inside the exhaust muffler that lower the sound levels created by the combustion of the engine. Page 195 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 7529 Application Table Part 3 Page 520 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 10636 Circuit/System Testing Component Testing Page 10938 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Recall 04V046000: Erratic Wiper Operation Wiper Control Module: All Technical Service Bulletins Recall 04V046000: Erratic Wiper Operation DEFECT: The windshield wipers on these sport utility vehicles may fail to turn on, unexpectedly stop working, fail to turn off/on by themselves (moisture sensitive wiper system), or the washer pump may operate continuously because water can enter the wiper module and either cause a short circuit or corrosion of components within the module. Driver visibility could be reduced, which could result in a crash. REMEDY: Dealers will cover the windshield wiper module vent hole with a patch. Also, the wiper motor, circuit board, and electrical connector will be inspected for signs of water intrusion and/or corrosion and be replaced as required. The manufacturer has reported that owner notification is expected to begin during the third quarter of 2004. Owners may contact Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Oldsmobile at 1-800-630-6537. Page 6828 Registered And Non-Registered Trademarks Part 6 Page 13179 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the grille. 6. Remove sensor bracket from bumper. 7. Remove the Connector Position Assurance (CPA) from both (2) electronic frontal sensor (EFS) connectors. IMPORTANT: This vehicle is equipped with two inflatable restraint electronic frontal sensors (EFS). When performing this procedure be sure to include both EFS's. 8. Disconnect both EFS connectors. Zone 2 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 5052 Disclaimer Page 10535 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 9541 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 10786 Passlock Sensor Page 13978 Steps 1-5 Page 6421 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8436 Cabin Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2 wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and low reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0-5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the following conditions: The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 9916 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 9084 5. Remove the nut (1) securing the retractor assembly (2) to the seat back frame. 6. Remove the retractor assembly. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the nut (1) securing the retractor assembly (2) to the seat back frame. Tighten Tighten the center seat belt retractor mounting nut to 55 N.m (40 lb ft). Page 12998 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 12523 Conversion - English/Metric Part 1 Page 2783 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 9526 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 4139 Abbreviations And Meanings Part 25 Page 9886 Memory Seat Switch, Driver Door Module (DDM) - C4 Locations Engine, Left Front Page 13116 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 13706 Combination Switch: Diagrams Turn Signal /Mutifuction Switch C1 Page 6938 Application Table Part 3 Location View Page 12348 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lift up on the front edge of the door lock and side window switch (1) in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. Remove the electrical connector (2) from the memory seat switch. 4. Remove the memory seat switch from the lock and door lock and side window switch (1). INSTALLATION PROCEDURE Page 5392 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Page 13740 Turn Signal Switch: Service and Repair Multifunction Turn Signal Switch Housing Replacement Multifunction Turn Signal Switch Housing Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the steering wheel from the column. 3. Remove the ignition lock cylinder case assembly. 4. Remove the turn signal and multifunction switch assembly. 5. Slide the turn signal switch housing off of the steering column shaft assembly. Installation Procedure Important: The turn signal switch housing must be pressed firmly against the steering column tilt head in order for the screws from the turn signal and multifunction switch assembly screws to line up. 1. Slide the turn signal switch housing onto the steering column shah assembly. 2. Install the turn signal and multifunction switch assembly. 3. Install the ignition lock cylinder case. 4. Install the steering wheel onto the column. 5. Enable the SIR system. Page 4269 Abbreviations And Meanings Part 3 Page 8341 Page 12716 DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Page 7110 C311 CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. The scan tool instructs you to perform the following items: - Accelerate to wide open throttle (WOT). - Release the throttle when fuel cut-off occurs. - Observe the fuel cut-off for the engine that you are performing the learn procedure on. - The engine should not accelerate beyond calibrated RPM value. - Release the throttle immediately if value is exceeded. - Block the drive wheels. - Set the parking brake. - DO NOT apply the brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn the A/C OFF. - The vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. With the scan tool, enable the crankshaft position system variation learn procedure. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release the throttle when the fuel cut-off occurs. 8. The scan tool displays Learn Status-Learned this ignition: - If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. - If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. - If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The crankshaft position system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P1336 sets: Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - Crankshaft position sensor replacement - Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Page 8406 Abbreviations And Meanings Part 26 Page 10560 Specifications Water Pump: Specifications Water Pump Bolts ................................................................................................................................ ................................................. 10 Nm (89 inch lbs.) Page 13477 area. Important: ^ Use a clean low lint towel or towelette and wipe the glass, only removing the excess adhesive promoter from the lift gate glass. ^ Do not wipe the glass dry. ^ Allow the liftgate glass to air dry completely. ^ The applique must be installed within 30 minutes following the use of the promoter. 16. Allow the adhesive promoter to remain on the glass surface for a minimum of 10 seconds. 17. Attach the CHMSL wire to the connector and install the grommet. 18. Slide the liftgate glass on the hinge pins to the left in order to allow clearance for the locating hooks. 19. Remove the protective liner from the tape on the applique. 20. Attach the locating hooks on the applique to the hinge pins. 21. Apply the applique to the liftgate glass. 22. With the heel of your hand, and starting from center of the applique and working outward towards each outer edge, apply even and consistent pressure ensuring complete contact of the adhesive strip to the glass. 23. Install the screws that retain the applique to the liftgate glass. Tighten Tighten the screws to 5 N.m (44 lb in). Important: The vehicle must be kept dry and at 21°C (70°F) to 43°C (110°F) for no less than 4 hours to ensure proper adhesive cure time. 24. Clean the liftgate glass and applique area. Parts Information Parts are currently available from GMSPO. Warranty Information Page 13251 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 1686 Window Switch, LR Diagrams Timing Chain Alignment Diagram Initial Inspection and Diagnostic Overview Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - GARAGE DOOR OPENER Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure to use when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Garage Door Opener in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures Panel Replacement Rear Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Rear Door Tools Required J 36796 Clip Removal Tool Removal Procedure 1. Remove the cover from the trim panel. 2. Remove the 2 retaining screws from the trim panel. 3. Remove the power window switch. 4. Use the J 36796 in order to release the fasteners that retain the trim panel to the door. 5. Remove the trim panel from the door. Installation Procedure 1. Install the trim panel to the door, ensuring that all the retaining tabs are fully seated. 2. Install the power window switch. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 2 retaining screws to the trim panel. Tighten the screws to 2.5 N.m (22 lb in). 4. Install the cover to the trim panel. Page 7660 Tighten the power steering pressure hose to the power steering pump to 25 Nm (18 ft. lbs.). 4. Install the power steering hose assembly to front crossmember bracket mounting bolt. Tighten the power steering hose assembly to front crossmember bracket mounting bolt to 10 Nm (89 inch lbs.). 5. Install the power steering hose assembly to frame brackets retaining bolts. Tighten the power steering hose assembly to frame brackets retaining bolts to 10 Nm (89 inch lbs.). 6. Connect the power steering hose assembly bracket to the wheel well. 7. Install the power steering hose assembly bracket retaining bolt at the wheel well. Tighten the power steering hose assembly bracket retaining bolt at the wheel well to 10 Nm (89 inch lbs.). 8. Install the fuse block. 9. Install the battery tray. 10. Connect the fuse block harnesses to the wiring loops. 11. Raise the vehicle. 12. Install the power steering return hose and the power steering cooler hose to the power steering cooler. 13. Remove the power steering gear oil seals from the power steering gear using J44586. Notice: Clean the power steering gear inlet and outlet ports thoroughly of any debris. Failure to do so could result in contamination and damage to the power steering system components. 14. Clean the power steering gear inlet and outlet ports of any debris. 15. Install the power steering gear oil seals to the power steering gear using J44586. Page 11612 Console: Service and Repair Console Storage Bin Replacement Console Storage Bin Replacement Removal Procedure 1. Open the storage bin cover. 2. Remove the 6 screws that retain the storage bin to the console. 3. Remove the storage bin from the console. Installation Procedure 1. Install the storage bin to the console. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 6 screws that retain the storage bin to the console. Tighten the screws to 2.5 N.m (22 lb in). 3. Close the storage bin cover. Page 2663 Drive Belt Vibration Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Page 5129 For vehicles repaired under warranty, use the table. Disclaimer Page 11834 Abbreviations And Meanings Part 19 Page 3899 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 8522 3. Disconnect the electrical connector. 4. Remove the rear HVAC control-auxiliary from the vehicle. INSTALLATION PROCEDURE 1. Connect the rear HVAC control-auxiliary electrical connector. 2. Install the HVAC control-auxiliary in the console bottom first. 3. Push in at the top of the HVAC control-auxiliary in order to engage the HVAC control-auxiliary in the console/seat. Page 4275 Abbreviations And Meanings Part 9 Page 1559 Seat Belt Switch-LF Page 4369 1. Install the PCM mounting studs to the intake manifold, if removed. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the studs to 6 N.m (53 lb in). 2. Install the PCM (2) to the intake manifold. 3. Install the PCM mounting nuts and bolts (4). Tighten Tighten the nuts and bolts to 10 N.m (88 lb in). 4. Install the PCM harness connectors (3) to the PCM body. 5. Tighten the PCM harness connector retaining bolts (1). Tighten Tighten the bolts to 8 N.m (71 lb in). 6. If a new PCM is being installed, the PCM must be programmed. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. See: Testing and Inspection/Programming and Relearning Procedures Power Door Lock Switch: Procedures Switch Replacement - Door Lock and Side Window - Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle INSTALLATION PROCEDURE 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. 4. If replacing the driver door module, program the driver door module. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming and Personalization Description and Operation in Personalization. IMPORTANT: When replacing the driver door module, the set up procedure must be performed. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Service and Repair Condenser HVAC: Service and Repair Air Conditioning Condenser Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. 2. Remove the compressor discharge hose nut (1) from the condenser. 3. Remove the compressor discharge hose (2) from the condenser. 4. Remove the hood latch. 5. Remove the head lamp housing panel. 6. Remove the radiator diagonal brace. 7. Remove the bolts from the upper radiator support. 8. Remove the upper radiator support. 9. Remove the evaporator tube nut (5) from the condenser. 10. Remove the evaporator tube (4) from the condenser. 11. Remove the studs from the condenser inlet and outlets. 12. Remove the condenser LH upper bracket bolt and bracket. 13. Remove the condenser to radiator bolts. 14. Remove the condenser from the radiator. Page 1915 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 3201 Coolant Outlet: Service and Repair Water Outlet Housing Replacement Removal Procedure 1. Disconnect the outlet radiator hose from the water outlet housing. 2. Remove the power steering pump bracket. 3. Remove the water outlet bolts. 4. Remove the water outlet. Installation Procedure 1. Install the water outlet. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the water outlet bolts. Tighten the water outlet bolts to 10 Nm (89 inch lbs.). 3. Connect the outlet radiator hose to the water outlet housing. 4. Install the power steering pump bracket. Page 144 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 1737 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 9351 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 232 Page 6575 Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Remove the accessory trim plate. 2. Disconnect the electrical connector from the traction control switch. 3. Release the traction control switch locking tabs located behind the trim plate. 4. Remove the traction control switch from the trim plate Installation Procedure 1. Position the traction control switch to the trim plate 2. Install the traction control switch to the instrument panel trim plate by seating the locking tabs. 3. Connect the electrical connector to the traction control switch. 4. Install the accessory trim plate. Page 1289 Lifgate Ajar Switch Page 321 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 12011 WA387E/57 - WA408G/44 Page 5730 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 11702 1. Remove the front and rear door sill plates. 2. Move the seat to a forward position. 3. Release the 4 retaining clips that attach the garnish molding to the center pillar. 4. Disconnect the electrical connector from the temperature sensor, if equipped. 5. Remove the garnish molding from the vehicle. INSTALLATION PROCEDURE 1. Position the garnish molding to the center pillar. 2. Connect the electrical connector to the temperature sensor, if equipped. 3. Index the positioning tabs on the garnish molding to the corresponding holes in the center pillar. 4. Seat the 4 garnish molding retaining tabs to the center pillar. 5. Return the seat to neutral position. 6. Install the front and rear door sill plates. Garnish Molding Replacement - Rear Window GARNISH MOLDING REPLACEMENT - REAR WINDOW REMOVAL PROCEDURE 1. Open the liftgate. Page 6142 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 79 Abbreviations And Meanings Part 24 Page 618 Registered And Non-Registered Trademarks Part 4 Page 13497 For vehicles repaired under warranty, use the table. Disclaimer Page 10177 Page 8345 Description and Operation Temperature Warning Lamp/Indicator: Description and Operation Engine Coolant Indicator ENGINE COOLANT HOT IDLE ENGINE The radio activates an audible warning as requested by the Instrument Panel Cluster (IPC). The IPC sends a class 2 message to the radio indicating the chime duration of 4 pulses. The warning sounds and the appropriate indicator illuminates in the Driver Information Center (DIC) when the following occurs: - The IPC determines that the coolant temperature is greater than 125°C (257°F). The IPC receives a class 2 message from the PCM indicating coolant temperature. - The IPC performs the displays test at the start of each ignition cycle. The indicator illuminates for approximately 3 seconds. The IPC turns OFF the engine coolant indicator when the engine coolant falls below 122°C (252°F). Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 2038 IMPORTANT:The length of the replacement line must be the same as the section being replaced. 8. Use the cleaning pad from the J 41425 in order to clean any burrs or grease from the line ends. Be sure to clean at least 19 mm (0.75 in) from the line splice area. 9. Use the LOK prep sealant in order to prep the line ends. 10. Apply one drop of the J 41425-3 sealing compound to the outside of each end of the line. 11. Insert the line ends into the LOK fitting. 12. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 13. Install the correct LOK fitting jaws into the J 41425-1 tool. 14. Install the J 41425-1 tool over the LOK connectors.Verify that the LOK connector ends are positioned in the counter bores of the jaws. 15. Tighten the forcing screw of the J 41425-1 tool.When fully seated, the LOK connector collars will bottom out on the center shoulder of the LOK fitting. IMPORTANT:Hold the J 41425-1 tool body with a 3/8" breaker bar. 16. Loosen the forcing screw and remove the J 41425-1 tool from the repaired line. 17. Repeat Step 8 through Step 16 to complete the line splice. 18. Verify that the LOK fittings are correctly installed. 19. Lower the vehicle. 20. Refill the coolant, if drained. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 21. Evacuate and recharge the refrigerant, if repairing the A/C lines. Line Sectioning Repair HEATER AND AIR CONDITIONING (A/C) PIPE REPLACEMENT/REPAIR - AUXILIARY TOOLS REQUIRED J 41425 A/C Line Repair Kit Do not service the rear A/C or heater lines as a complete unit. Service the rear A/C or heater lines as a sectional repair. You can obtain the various sections of line through GMSPO. Use the J 41425 when any of the following actions damage the rear A/C or heater lines: - Rub-through - Collision damage - Leakage in the system Page 5638 Disclaimer Page 9509 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 10907 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Page 9161 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 9095 Electronic Frontal Sensor - Right Page 9507 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 133 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 9989 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 10685 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 9796 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts PROM - Programmable Read Only Memory: Customer Interest Engine Controls Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 2064 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Page 13129 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Description and Operation Traction Control Indicator Lamp: Description and Operation Traction Control Indicators (w/NW7) LOW TRACTION The low traction indicator is part of the traction control switch. The EBCM applies ground to the traction control active signal circuit in order to illuminate the low traction indicator during a traction control event. TRACTION OFF The traction off indicator, which is part of the traction control switch, turns OFF when ground is applied to the service traction control signal circuit. The EBCM illuminates the traction off indicator if any of the following conditions are present. ^ The EBCM inhibits the traction control system. ^ The driver manually disables the traction control system by pressing the traction control switch. ^ The automatic transmission shift lever is in the low (1) position. The EBCM inhibits the traction control system when a TCS-disabling malfunction occurs, or when the automatic engagement feature is programmed to disable the TCS when the ignition is turned ON. Refer to Programming the Traction Control Automatic Engagement Feature. Page 8307 34. Install the coolant bypass valve to its original location and secure with a nut. 35. Connect the other end of the new hose from step 29 to the outlet port of the auxiliary heater pump. 36. Connect the vacuum hose to the coolant bypass valve. 37. Connect the coolant bypass valve hose to the auxiliary rear heater line. 38. Install the heater hose quick connect retainers to the heater core pipes. 39. Connect the remaining two hoses to the heater core. 40. Install the new auxiliary heater pump wiring harness to the vehicle. Page 12895 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 12312 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement (TrailBlazer, Envoy, Bravada)Headliner Replacement (TrailBlazer EXT, Envoy XL) in Interior Trim. 2. Disconnect the inline connector from the sunroof electrical harness. 3. With an assistant, remove the sunroof module assembly from the vehicle and place on a clean, prepared surface. 4. Remove the sunroof motor/actuator. 5. Remove the screw that retains the sunroof control module to the mounting bracket. 6. Disconnect the 2 electrical connectors from the sunroof control module. 7. Remove the sunroof control module from the mounting bracket. INSTALLATION PROCEDURE 1. Position the sunroof control module to the mounting bracket. IMPORTANT: Ensure that the drive gear is fully indexed and seated to the drive cables. 2. Install the screw that retains the sunroof control module to the mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the sunroof control module screw to 3 N.m (27 lb in). 3. Connect the 2 electrical connectors to the sunroof control module. 4. Install the sunroof motor/actuator to the sunroof module assembly. 5. With an assistant, install the sunroof module assembly to the vehicle. 6. Connect the inline connector on the sunroof electrical harness. 7. Install the headliner. Page 870 Abbreviations And Meanings Part 15 Page 11773 Page 8365 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 7606 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Diagrams Oil Level Sensor For ECM: Diagrams Engine Oil Level and Temperature Sensor Page 5393 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Page 6888 Abbreviations And Meanings Part 3 Engine - Redesigned Oil Pick-Up and Front Cover Timing Cover: Technical Service Bulletins Engine - Redesigned Oil Pick-Up and Front Cover Bulletin No.: 04-06-01-015 Date:May 24, 2004 INFORMATION Subject: New Design Oil Pick Up Tube and Front Cover Models: 2004 Buick Rainier 2002-2004 Chevrolet Trailblazer 2002-2004 GMC Envoy 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Page 9799 Conversion - English/Metric Part 1 Page 13928 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 13965 Rear Window Defogger C2 Page 10557 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 4944 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils Page 670 Memory Seat Module - Passenger C4 Part 2 Page 9529 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 4946 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Turn OFF the ignition switch. 2. Remove the ignition coils. Refer to Ignition Coil Replacement. Notice: Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. Notice: Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure Notice: Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. Notice: Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gauge to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. Refer to Ignition System Specifications, See: Specifications Correct as necessary. Notice: Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Instruments - Erratic Speedometer Operation Ground Strap: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 2737 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine oil pan drain plug and drain the engine oil. 3. Remove the engine protection shield mounting bolts. 4. Remove the engine protection shield. 5. Disconnect the electrical connector from the engine oil level sensor. 6. Remove the engine oil level sensor mounting bolt. 7. Remove the engine oil level sensor. Page 8393 Abbreviations And Meanings Part 13 Heater Case/Cover Replacement Heater Core: Service and Repair Heater Case/Cover Replacement HEATER CORE COVER REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the screws from the heater core cover-auxiliary (3). 3. Remove the heater core cover-auxiliary (3). INSTALLATION PROCEDURE 1. Install the heater core cover-auxiliary (3). 2. Install the screws to the heater core cover-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to ......2 N.m (18 lb in). 3. Install the right rear quarter trim panel. Page 8508 HVAC Control Module-Auxiliary (Body Type VIN 3) Part 1 A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 1019 34. Install the coolant bypass valve to its original location and secure with a nut. 35. Connect the other end of the new hose from step 29 to the outlet port of the auxiliary heater pump. 36. Connect the vacuum hose to the coolant bypass valve. 37. Connect the coolant bypass valve hose to the auxiliary rear heater line. 38. Install the heater hose quick connect retainers to the heater core pipes. 39. Connect the remaining two hoses to the heater core. 40. Install the new auxiliary heater pump wiring harness to the vehicle. Page 8207 Instrument Panel Carrier, Cowl Side Lower Console (w/Automatic - HVAC System) (Body Type VIN 6) Page 8304 29. Install the auxiliary heater pump and bracket onto the dash panel studs. 30. Reinstall the HVAC plate and nuts. 31. On the coolant bypass valve, remove the hose (1) that went from the valve to the engine and discard. Page 12626 Seat Adjuster Switch - Driver (w/o Memory) Part 1 Page 8723 Refrigerant: Service Precautions DETECTOR PRECAUTION CAUTION: Do not operate the detector in a combustible atmosphere since its sensor operates at high temperatures or personal injury and/or damage to the equipment may result. REFRIGERANT R-134A PRECAUTION CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Page 11804 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 6253 4. Apply high temperature silicone brake lubricant to the brake caliper guide pins. DO NOT apply the lubricant to the brake pad retaining clips. 5. Install the brake caliper mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the caliper mounting bracket bolts. ^ Tighten the caliper mounting bracket bolts to 70 Nm (52 ft. lbs.). 7. Install the rear brake pad hardware to the brake caliper mounting bracket. 8. Install the brake pads to the brake caliper mounting bracket. Page 6329 Brake Bleeding: Service and Repair Pressure Bleeding Procedure Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder- loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 35589-A. 8. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. Page 2246 Fuse Block - Underhood C6 Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 6643 Page 2957 Registered And Non-Registered Trademarks Part 3 Page 6655 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: All Technical Service Bulletins Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11820 Abbreviations And Meanings Part 5 Page 8846 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Page 1762 Abbreviations And Meanings Part 26 Page 93 Steps 4-6 The numbers below refer to the step numbers on the diagnostic table. 1. This step verifies that the RAP power mode function is malfunctioning by checking functions internally enabled by the BCM. 4. The BCM sends Class 2 messages to other control modules via the serial data link, allowing them to operate in RAP power mode. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 5. This step is checking for DTCs in the BCM. 6. The presence of DTCs which begin with "U" indicate that other module is not communicating. The specified procedure will compile all the available information before tests are performed. Page 576 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 9300 Passlock Sensor Page 8053 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 5497 Automatic Transmission Shift Lock Control Solenoid Page 856 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 5853 8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the C-lock (1) until the C-lock aligns with the thrust block (2). 9. Push the flange of the axle shaft (1) toward the differential. 10. Remove the C-lock from the button end of the axle shaft. Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Maligning the gears will make the installing of the axle shaft difficult. 11. Remove the axle shaft from the housing. Installation Procedure Important: Carefully insert the axle shaft in order to not damage the seal. Page 5516 For vehicles repaired under warranty, use the table. Disclaimer Page 2702 2. Add sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil level indicator tube stud threads. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 3. Install the oil level indicator tube stud. Tighten the oil level indicator tube stud to 10 Nm (89 inch lbs.). 4. Install the A/C line bracket to oil level indicator tube and secure with the nut. Tighten the A/C line bracket nut to 7 Nm (6 inch lbs.). 5. Connect the 02 sensor electrical connector. 6. Install the oil level indicator into the tube. Page 6703 Abbreviations And Meanings Part 25 Page 9056 Buckle Replacement - No. 2 Rear REMOVAL PROCEDURE 1. Remove the seat assembly from the vehicle. 2. Remove the grommet (1). Discard the old grommet. 3. Remove the seat belt buckle assembly from the seat. INSTALLATION PROCEDURE 1. Install the seat belt buckle assembly onto the seat. Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Weatherstrip Run Channel Assembly Replacement - Front Removal Procedure 1. Remove the door trim panel. 2. Remove the speaker. 3. Remove the water deflector. 4. Remove the window. 5. Remove the 2 bolts that retain the weatherstrip/run channel to the door. 6. Pull the weatherstrip/run channel away from the window frame opening. 7. Carefully twist and pull up on the weatherstrip/run channel, in order remove the weatherstrip/run channel from the top of the door frame. 8. Remove the weatherstrip/run channel from the door. Installation Procedure 1. Install the weatherstrip/run channel to the door. 2. Position the tabs on the weatherstrip/run channel into the slots in the door. 3. Press the weatherstrip/run channel into the window frame opening. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 retaining bolts. Tighten the retaining bolts to 10 N.m (88 lb in). 5. Install the window. 6. Install the water deflector. 7. Install the speaker. 8. Install the door trim panel. Page 3745 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Page 11695 2. Lower the headliner in order to gain access to the wire harness. 3. Position the sunshade to the headliner. 4. Connect the sunshade electrical connector to the headliner harness. 5. Using a glue gun, hot melt the electrical connectors (1) to the headliner substrate, ensuring the connectors are securely attached to the substrate. 6. Route the wire harness until fully seated into the sunshade wire harness channel located on the pivot arm. Important: If the wire harness retaining clip is removed from the sunshade for any reason, a new retaining clip must be installed. 7. Position the wire harness retaining clip between the headliner and the roof panel. 8. Position the index tabs on the wire harness retaining clip to the pivot arm and install the clip until fully seated. With the wire harness retaining clip installed, the sunshade should remain attached to the headliner. 9. Position the inboard retainer (1) to the roof panel. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the inboard retaining screw. Tighten the screw to 1.2 N.m (10 lb in). Page 4108 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 10689 Parts Information Page 10669 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 12154 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 3394 1. Install the thermostat housing at the water inlet to the engine block. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the thermostat housing bolts. Tighten the bolts to 10 Nm (89 inch lbs.). 3. Lubricate the inner diameter of the radiator hose with engine coolant. 4. Install the outlet hose to the thermostat housing (1). Secure the hose with the clamp. 5. Install the generator. 6. Fill the cooling system with specified coolant and concentration. 7. Inspect all sealing surfaces for leaks after starting the engine. Page 13203 Odometer: Description and Operation ODOMETER The base IPC contains a season odometer and a trip odometer. The uplevel IPC contains a season odometer and two trip odometers. Momentarily press the trip/reset switch on the IPC in order to toggle between the season odometer and the trip odometer. Press the trip/reset switch for greater than 2 seconds, while the trip odometer is displayed, in order to reset the trip odometer. The IPC calculates the mileage based on the vehicle speed signal circuit from the PCM. The odometer will display 'error' if an internal IPC memory failure is detected. The odometer displays either miles or kilometers as requested by the activation of the Personalization button on the steering wheel controls. Page 1375 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 9726 1. Install the video assembly to the vehicle. IMPORTANT: Ensure the lock washers are fully seated, completely exposing the bolt threads. 2. Lift the and adjust the video assembly in order to install the T-hook (1) to the video player bracket. Ensure the T-hook is fully seated to the bracket. 3. Support the front of the video assembly and connect the video assembly electrical connector (2). 4. Align the retaining fastener (3) to the corresponding hole in the video player bracket. 5. Raise the front of the video assembly to install the retaining fastener (3). 6. Partially install the rear retaining bolts. 7. Adjust the video display screen to a full open position. 8. Partially install the front retaining bolts. 9. Fully seat the retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 9 N.m (80 lb in). 10. Verify the video display for proper operation. 11. Close the video display screen. 12. Install the bolt cover bezel. Page 2332 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Page 13248 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 10927 Auxiliary Step / Running Board: Service and Repair Assist Step Replacement Assist Step Replacement Removal Procedure 1. Remove the nuts (1) that retain the assist step to the assist step support brackets. 2. Remove the assist step from the support brackets. 3. Place the assist step on a clean, prepared surface. 4. Release the fasteners (2) that retain the assist step pad to the assist step. 5. Remove the assist step pad from the assist step. Installation Procedure 1. Install the assist step pad to the assist step, ensuring that the fasteners (2) are fully seated. 2. Position the assist step to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Install the nuts (1) that retain the assist step to the assist step support brackets. Tighten the nuts to 25 N.m (18 lb ft). Page 6880 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 5588 Torque Converter Clutch Solenoid: Diagrams Torque Converter Clutch Pulse Width Modulated (TGC PWM) Solenoid Valve Connector, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side Page 636 Door Control Module Diagram 3 Page 12347 Memory Seat Switch, Driver Door Module (DDM) - C4 Page 1973 Drive Belt Vibration Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure. Page 9499 Page 9853 Non-Compatible Garage Door Openers NON-COMPATIBLE GARAGE DOOR OPENERS Page 819 Page 7415 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 2199 Application Table Part 1 Page 6981 Fuse Block - Underhood C4 Part 3 Page 3045 Steps 4-7 Page 4374 Accelerator Pedal Position (APP) Sensor Page 77 Abbreviations And Meanings Part 22 Page 554 Page 5012 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 8202 Instrument Panel Carrier, Left And Right Page 11852 Mirror Connector, Driver Door Module (DDM) - C3 Part 1 OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Page 8499 HVAC Control Module C2 Page 9504 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 9665 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 424 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 12835 Abbreviations And Meanings Part 12 Page 7188 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 6305 6. Compress the front brake caliper piston. 6.1. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. 6.2. Slowly tighten the C-clamp until the piston pushes into the brake caliper enough to slide the brake caliper off the rotor. 6.3. Remove the C-clamp from the brake caliper. 7. Remove the rear brake caliper mounting bracket. 8. Remove the brake rotor retaining clips, if equipped. Page 13284 Abbreviations And Meanings Part 22 Page 7519 4. Install the harness end bolts (2). 5. Install the fuse relay center cover (1) over the relay center bolts. Press downward to engage the tabs. 6. Install the junction block cover. Press downward to engage the tabs. Page 1051 16. Inspect the inside of the electrical connector on the wiper motor for moisture or water. If no moisture or water is found, continue inspecting for evidence or signs that moisture or water was present at some earlier time. Indicators include water stains, dried dirt, etc. (1). ^ If moisture or water is found in the electrical connector, or if there is evidence that there was moisture or water present at an earlier time, the complete wiper motor module (including the motor) MUST be replaced. Obtain a new wiper module and proceed to Step 20. The new wiper modules already have a different style of breathable seal on the wiper cover. DO NOT install the breathable seal described later in this recall on new wiper modules. ^ If there is no moisture or water found in electrical connector, or if there is NO evidence that moisture or water was present at an earlier time, a breathable seal must be installed over the vent in the wiper motor cover. Proceed to the next step. 17. Clean the exterior surface of the wiper motor cover thoroughly (1). It must be free of dirt, grease, oil, and other contamination. Important To ensure good adhesion of the seal being installed in the next steps, make sure that your hands are clean and free of oil and grease before proceeding. 18. Using the alcohol wipe included in the kit, wipe the complete exterior surface of the wiper cover thoroughly. Allow the surface to dry approximately 30-45 seconds before proceeding. Important When using the adhesion promoter in the next step: ^ DO NOT open the adhesion promoter until you are ready to apply it. ^ Use the complete contents of the packet as soon as it is opened. ^ If the packet is dried-out when opened, obtain another sealer kit or use P/N 12378462 (4 oz. can of adhesion promoter). ^ Do not allow the liquid to "spill" inside of the vent opening on the wiper motor cover when applying. ^ Allow to dry 30-90 seconds before applying the seal. 19. Carefully apply the adhesion promoter that is included in the kit. Important The seal must be inspected before installing. If there are any creases in the seal or backing material, the seal must NOT be used. Obtain another sealer kit. ^ If you are unable to remove the backing material from the seal in the next step, the seal is beyond its shelf life of one year. Obtain another sealer kit. Do NOT touch the adhesive surface on the seal when removing the backing material. Page 13498 Center High Mounted Stop Lamp (CHMSL) Page 7388 9. Install the 3 bolts (1) that retain the junction block to the block base. Tighten Tighten the 3 bolts to 3.5 N.m (31 lb in). 10. Install the BCM to the rear electrical center. 11. Install the battery feed terminal nut (2) to the junction block. Tighten Tighten the battery feed terminal nut to 10 N.m (88 lb in). 12. Install the rear electrical center cover. 13. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a passenger position. 14. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 15. Connect the battery negative cable. Page 7590 Disclaimer Page 3641 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor (1) from the air duct with a twisting and pulling motion. INSTALLATION PROCEDURE 1. Install the IAT sensor (1) to the air duct with a pushing and twisting motion. 2. Reconnect the IAT sensor electrical connector. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Engine Controls - Underhood Ticking Noise Fan Clutch: All Technical Service Bulletins Engine Controls - Underhood Ticking Noise Bulletin No.: 05-06-02-004 Date: April 06, 2005 TECHNICAL Subject: Underhood Tick Noise at Idle (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada Condition Some customers may comment on an underhood tick noise heard while the vehicle is idling. Technicians may find that the noise does not increase or decrease with changes in the engine idle RPM. The tick noise occurs at approximately one second intervals. Cause This condition may be caused by the electro-viscous fan clutch control function of the Powertrain Control Module (PCM) attempting to keep the fan speed between 300-600 revolutions per minute (RPM). At idle, the cooling fan speed will drag to approximately 500 RPM then oscillate between 300 and 600 RPM. When the fan speed drops below 500 RPM, the PCM will pulse the fan control solenoid. The pulsing of the solenoid is the cause of the ticking noise. Correction Technicians are to verify that the cooling fan clutch is the source of the noise by using either one of the following two methods: ^ Use a Tech 2(R) to command the cooling fan off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. ^ The cooling fan clutch electrical connector, located on the cooling fan shroud, may be disconnected with the engine off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. Be sure to clear any Diagnostic Trouble Codes (DTCs) that may have set while the cooling fan clutch is disconnected. Technicians are to reprogram the PCM with an updated software calibration. The new software calibration is currently available in TIS for all the vehicles listed above. Warranty Information Page 10522 Page 12266 Luggage Rack: Service and Repair Luggage Carrier Slats Replacement Luggage Carrier Slats Replacement Tools Required J 25070 Heat Gun Removal Procedure 1. Mark the location of the luggage carrier slats on the roof with masking tape. 2. Use tape to protect the mounting surface during removal. 3. To remove the luggage carrier slats, heat the slats using J 25070. Apply heat in a circular motion for 30 seconds. Notice: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate. 4. Use a plastic, flat-bladed tool to lift or remove the slats from the vehicle. 5. Remove the luggage carrier slats from the vehicle. 6. When replacing the slats, remove all of the adhesive using a 3M(TM) Scotch Brite molding adhesive remover disk, 3M(TM) P/N 07501 or equivalent. Installation Procedure Important: Apply the slats in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Heat the mounting surface to approximately 27-41°C (80-105°F). 2. Ensure that the temperature of the slats is approximately 29-32°C (85-90°F). Important: Do NOT touch the adhesive backing. 3. Remove the backing from the adhesive on the slats. 4. Align the luggage carrier slats with the masking tape. 5. Install the luggage carrier slats to the vehicle. 6. Apply equal pressure along the slats in order to uniformly bond the item to the mounting surface. 7. Remove the masking tape from the vehicle. Page 5094 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Page 2334 Tires: Technical Service Bulletins Tires - Correct Inflation Pressure Information INFORMATION Bulletin No.: 00-00-90-002J Date: January 28, 2009 Subject: Information on Proper Tire Pressure Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3, H3T 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and clarify additional information. Please discard Corporate Bulletin Number 00-00-90-002I (Section 00 - General Information). Important: ^ Adjustment of tire pressure for a customer with a Low Tire Pressure Monitor (TPM) light on and no codes in the TPM system is NOT a warrantable repair. Claims to simply adjust the tire pressure will be rejected. ^ ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on the vehicle's tire placard (on driver's door) during the PRE-DELIVERY INSPECTION (PDI). Recommended inflation pressure is not the pressure printed on tire sidewall. ^ Tires may be over-inflated from the assembly plant due to the mounting process. ^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure change. ^ 2008-2009 HUMMER H2 Only - The H2 comes standard with Light Truck "D" Load Range tires with a recommended cold inflation pressure of 289 kPa (42 psi). These tires will alert the driver to a low pressure situation at roughly 262 kPa (38 psi) due to a requirement in FMVSS 138 which specifies a Minimum Activation Pressure for each tire type. This creates a relatively narrow window of "usable" pressure values and the warning will be more sensitive to outside temperature changes during the colder months. As with other cold temperature/tire pressure issues, there is nothing wrong with the system itself. If a vehicle is brought in with this concern, check for tire damage and set all tires to the Recommended Cold Inflation Pressure shown on the vehicle placard. Accurate tire pressures ensure the safe handling and appropriate ride characteristics of GM cars and trucks. It is critical that the tire pressure be adjusted to the specifications on the vehicle¡C■s tire placard during PDI. Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure. The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct pressures. The recommended tire inflation pressure is listed on the vehicle¡C■s tire placard. The tire placard is located on the driver¡C■s side front or rear door edge, center pillar, or the rear compartment lid. Tip ^ Generally a 5.6°C (10°F) temperature increase will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure increase. ^ The definition of a "cold" tire is one that has been sitting for at least 3 hours, or driven no more than 1.6 km (1 mi). ^ On extremely cold days, if the vehicle has been indoors, it may be necessary to compensate for the low external temperature by adding additional air to the tire during PDI. ^ During cold weather, the Tire Pressure Monitor (TPM) indicator light (a yellow horseshoe with an exclamation point) may illuminate. If this indicator turns off after the tires warm up (reach operating temperature), the tire pressure should be reset to placard pressure at the cold temperature. ^ The TPM system will work correctly with nitrogen in tires. ^ The TPM system is compatible with the GM Vehicle Care Tire Sealant but may not be with other commercially available sealants. Important: ^ Do not use the tire pressure indicated on the tire itself as a guide. Page 2224 Fuse Block - Rear C3 Part 3 Page 4466 Park/Neutral Position Switch (C2) Page 6257 1. Drain all the brake fluid from the caliper. 2. Pad the interior of the caliper with clean shop towels. Caution: Do not place your fingers In front of the piston in order to catch or protect the piston while applying compressed air. This could result In serious injury. Notice: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding. 3. Remove the piston from the caliper bore. 4. Remove the boot from the caliper bore. Do not scratch the housing bore. 5. Remove the piston seal from the caliper bore. Do not use a metal tool. Page 10835 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 239 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 11786 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 13114 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Specifications Camshaft Gear/Sprocket: Specifications Exhaust Camshaft Actuator Bolt First pass 18 ft. lbs. Second pass 135° Intake Camshaft Sprocket Bolt First pass 15 ft.lbs. Second Pass 100° Page 921 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5329 Fluid - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Removal Procedure 1. Open the hood. 2. Remove the rear hood seal from the inlet grille panel studs. 3. Remove the seal from the inlet grille panel. Installation Procedure 1. Position the seal to the inlet grille panel. 2. Install the rear hood seal to the inlet grille panel studs. 3. Close the hood. Page 9435 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 11851 Driver Door Module (DDM) - C2 Part 2 Page 9491 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 12144 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 11801 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 572 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 7342 Fuse Block - Rear C4 Part 2 Page 12528 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 11993 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 03-08-111-002G Date: 071221 Paint - Chips Behind Front Wheels/Front of Rear Wheels Page 8312 For vehicles repaired under warranty, use the table. Disclaimer Page 6291 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Page 8066 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 9876 3. Install the quick connector to the VCIM. 4. Install the remaining electrical connectors to the VCIM. 5. Install the VCIM (1) to the bracket. 6. Ensure the retaining tab (1) is fully seated. Page 12012 WA423G/79 - WA519F/12 Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Page 968 Inflatable Restraint Sensing And Diagnostic Module: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Page 4090 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 9805 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 1408 Intake Air Temperature (IAT) Sensor Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: All Technical Service Bulletins Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13321 Hood Hinge Bracket Hood Hinge: Service and Repair Hood Hinge Bracket Hood Hinge Bracket REMOVAL PROCEDURE 1. Remove all of the related panels and components. 2. Restore as much of the damage as possible to the factory specifications. 3. Note the location and remove the following as necessary: - Sealers - Sound deadeners - Anti-corrosion materials IMPORTANT: Do not damage any of the inner panels or reinforcements. Drill through the hinge bracket only. 4. Locate and drill out all factory welds. Note the number and location of welds for installation of the service part. 5. Remove the Hood Hinge Bracket. INSTALLATION PROCEDURE Page 11818 Abbreviations And Meanings Part 3 Page 13812 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 336 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 7975 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Page 2786 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Service and Repair Refrigerant Temperature Sensor: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the A/C low pressure switch electrical connector. 2. Remove the A/C low pressure switch (2) from the accumulator (1). 3. Remove and discard the O-ring seal from the A/C low pressure switch port on the accumulator. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the A/C low pressure switch (2) to the accumulator (1). Tighten the A/C low pressure switch to 4.8 N.m (42 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the A/C low pressure switch electrical connector. 4. Leak test the fittings of the components using the J 39400-A. Page 8965 2. Install the inflatable side impact module to the seat back frame with the 2 screws (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 9 N.m (80 lb in). 3. Install the top of the seat belt retractor assembly to the seat back frame with the plastic push pin (2). 4. Install the front seat back panel. 5. Install the seat back cover and pad. 6. Install the seat trim panel. 7. Install the seat assembly to the vehicle. 8. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 2 and SIR Disabling and Enabling Zone 6. Page 6555 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) C2 Electronic Brake Control Module (EBCM) C2 Part 1 of 2 Page 11784 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 7371 Application Table Part 1 Page 5170 3. Install the 1-2 and 2-3 Shift solenoids. 4. Install the 1-2 and 2-3 Shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. Page 12553 Abbreviations And Meanings Part 21 Page 8919 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Page 2560 11. Remove the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) from the cylinder block (100). Cylinder Sleeve Trimming EN 45680-865 Debris Collector (3) EN 45680-411 Trim Tool Assembly (2) Air Control Valve (1 Part of EN 45680-411) Drill Motor with 1/2 inch chuck, 11/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction Trim Tool Cutter Note: Please ensure that the cylinder bore sleeve trim tool has been updated with the new trimmer pilot. The old trimmer pilot, black in color for identification, may cause damage to the tool or to the sleeve. An updated trimmer pilot (EN-45680-499) was sent in November, 2004 to affected Chevrolet and GMC dealers. The new pilot is white in color, and should be installed on EN-45680-411 Trim Tool Assembly. Buick and HUMMER dealers were sent EN-45680-400 Cylinder Liner Replacer kit with the correct pilot already installed. Inspect EN-45680-411 to ensure the correct white pilot is installed. The trim tool cutter with the new trimmer pilot can be viewed from the bottom of the tool. Trim Tool Preloader (1) Page 3436 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 12521 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 8845 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 2759 Page 7605 Page 7328 Fuse Block - Rear C1 Part 2 Page 12747 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Opening Weatherstrip Replacement - Rear Door Opening Removal Procedure 1. Remove the rear door sill plate. 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. Instruments - Erratic Speedometer Operation Engine Control Module: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 10853 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 2570 Engine Block Heater: Description and Operation Coolant Heater The optional engine coolant heater (RPO K05) is rated at 400 watts and supplies 1365 btu/hr. The engine coolant heater operates using 110 volt AC external power and is designed to warm the coolant in the engine block area for improved starting in very cold weather -29°C (-20°F). The coolant heater helps reduce fuel consumption when a cold engine is warming up. The unit is equipped with a detachable AC power cord. A weather shield on the cord is provided to protect the plug when not in use. Page 4664 7. Remove the fuel rail attaching bolts. 8. Remove the fuel rail assembly. NOTE: Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. - Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages. 1. Remove the injector lower O-ring seal (4) from the spray tip end of each injector (3). 2. Discard the O-ring seals. 3. If the fuel rail is not being replaced, go to the Installation Procedure. DISASSEMBLY PROCEDURE 1. Remove the fuel injectors. 2. Remove the fuel pressure regulator. 3. Remove the fuel injector harness from the fuel rail. ASSEMBLY PROCEDURE 1. Install the fuel injector harness to the fuel rail. 2. Install the fuel pressure regulator. 3. Install the fuel injectors. INSTALLATION PROCEDURE Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 13957 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 10002 Page 10528 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 10174 Locations Electronic Components Page 6881 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 7741 Steering Gear: Service and Repair Steering Gear Cylinder Pipe ASSY/O-Ring Replace - Off Vehicle Steering Gear Cylinder Pipe Assemblies/O-Ring Seals Replacement - Off Vehicle Removal Procedure Important: Protect the boots from sharp tools and from the sharp edges of surrounding components. 1. Remove the TORX screw (1) from the cylinder line retaining plate (2) at the valve end. 2. Remove the cylinder line retaining plate (2). 3. Loosen both cylinder line nuts (3) on cylinder end of the gear assembly (1). 4. Remove both cylinder line assemblies (2) from the rack and pinion gear assembly (1). 5. Remove and discard the O-rings seals (4) from the valve end (5). Installation Procedure Page 406 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 12000 For all of the above vehicles except TrailBlazer SS install the assist step. For the TrailBlazer SS install a Protector Kit P/N 15783524. Instructions are included in the kit. Parts Information Repair Claim Information - Refer to the extent of the repair instructions as approved by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) Warranty Information (excluding Saab U.S. Models) Page 10223 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 7569 For vehicles repaired under warranty, use the table. Disclaimer Page 1077 Passlock Sensor Page 13060 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 7386 12. Disconnect the body wiring harness connector (1) from the junction block. 13. Disconnect the headliner harness connector (2) from the junction block. 14. Disconnect the console harness connector from the junction block. 15. Remove the block base retaining nuts from the floor studs. 16. Remove the block base from the floor panel. INSTALLATION PROCEDURE 1. Install the block base to the floor studs. 2. Install the block base retaining nuts to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the block base retaining nuts to 10 N.m (88 lb in). 3. Connect the console harness connector to the block base. 4. Connect the headliner harness connector (2) to the block base. 5. Connect the body wiring harness connector (1) to the block base. Locations Connector C201 Page 6617 Tighten the bolt to 50 N.m (37 lb ft). 4. Install the bolt that secures the harness to the wheelhouse panel (1). Tighten Tighten the bolt to 10 N.m (89 lb in). 5. Connect the negative battery cable to the battery. Page 10679 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 6515 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front passenger side seat. 2. Remove the park brake warning lamp switch electrical connector. 3. Remove the park brake warning lamp switch retaining screw. 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch retaining screw. ^ Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). 3. Connect the electrical connector. 4. Install the front passenger side seat. Page 13868 For vehicles repaired under warranty, use the table. Disclaimer Page 6126 Page 556 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 8372 Conversion - English/Metric Part 2 Page 3339 For vehicles repaired under warranty, use the table. Disclaimer Page 1759 Abbreviations And Meanings Part 23 Page 811 A/C - Musty Odors On Start Up Control Module HVAC: All Technical Service Bulletins A/C - Musty Odors On Start Up Bulletin No.: 05-01-39-002A Date: March 17, 2006 TECHNICAL Subject: Musty Odor from HVAC System (Reprogram HVAC Control Module to Enable Afterblow Function) Models: 2004-2006 Buick Rainier 2003-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2003-2004 Oldsmobile Bravada with Automatic Temperature Control HVAC System (RPO CJ2) Supercede: This bulletin is being revised to add the 2006 model year and update the calibration release date. Please discard Corporate Bulletin Number 05-01-39-002 (Section 01 - HVAC). Condition Some customers may comment on a musty odor from the Heating, Ventilation and Air Conditioning (HVAC) system. This condition occurs most often on initial start up after the vehicle was driven on a hot humid day. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. Correction Important: The afterblow function should not be enabled until after the purpose and operation of it is explained to your customer and they approve of the change. Once the afterblow function is enabled there are no calibrations currently released to disable it. Technicians are to reprogram the HVAC Control Module with an updated software calibration that will enable the afterblow function. The new calibration will be released beginning with TIS satellite data update version 2.0, which was made available February 5, 2006. The blower motor will turn on approximately 10 minutes after the vehicle is shut off. The blower motor will run continuously for 10 minutes at a 30% duty cycle. The afterblow function will only activate if the air conditioning compressor was engaged during conditions of high ambient temperature. If the vehicle is started within 10 minutes of the last key off, the afterblow function from the previous key cycle will be cancelled. Technicians should not attempt to reprogram a vehicle with a Manual Temperature Control HVAC system (RPO CJ3). Technicians should perform this HVAC Control Module reprogram instead of installing the Electronic Evaporator Dryer Module Kit referred to in the Air Conditioning Odor bulletin, Corporate Bulletin Number 99-01-39-004A. Warranty Information Locations Hazard Switch Page 268 Page 9171 Abbreviations And Meanings Part 4 Page 1205 6. Install the engine oil drain plug. ^ Tighten the engine oil drain plug bolt to 26 Nm (19 ft. lbs.). 7. Lower the vehicle. 8. Fill the crankcase with the proper quantity of engine oil. A/C - Poor Rear Heater Performance Auxiliary Water Pump: All Technical Service Bulletins A/C - Poor Rear Heater Performance Bulletin No.: 05-01-37-002A Date: November 01, 2005 TECHNICAL Subject: Poor Rear Heat Performance (Install Auxiliary Heater Pump) Models: 2003-2005 Chevrolet TrailBlazer EXT 2003-2005 GMC Envoy XL Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 05-01-37-002 (Section 01 - HVAC). Important: Implementation of this Service Bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on poor 2nd and/or 3rd row seating heater performance when the vehicle is at idle. Cause This condition may be due to lack of coolant circulation to the rear heater core. Correction Install auxiliary heater pump package, P/N 89024885 (L6 Engine RPO LL8) or P/N 89024886 (V8 Engine RPO LM4 or LH6). This pump will improve coolant flow to the rear heater core. Use the procedure listed below. 1. Recover the A/C refrigerant. 2. Drain the cooling system. 3. Disconnect the negative battery cable. 4. Remove the fender rear upper brace. 5. Remove the air cleaner cover. 6. Remove the air cleaner filter element and air outlet duct. 7. Remove the air inlet duct from the lower air cleaner housing/washer solvent tank assembly. 8. Disconnect the washer solvent tank electrical and remove wiring harness from the retaining clips. 9. Disconnect the washer pump hoses and plug the pump outlet ports to prevent loss of washer solvent. 10. Remove the two air cleaner housing/washer tank assembly retaining nuts from the mounting studs. 11. Lift the lower air cleaner housing/washer tank assembly off of the studs and remove the assembly. 12. On the A/C accumulator, disconnect the electrical connector from the low pressure switch. 13. Remove the compressor suction hose assembly from the accumulator. 14. Remove the nut retaining the accumulator to the evaporator. 15. Remove the coolant hoses from the coolant recovery reservoir. Page 6804 Abbreviations And Meanings Part 8 Page 8351 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Service and Repair Memory Positioning Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the 3 seat switch bezel screws. 2. Remove 4 nuts that attach the seat pan to the seat assembly. 3. Remove the clip from the front outboard seat pan stud. Discard the clip. 4. Lift the seat pan up in order to allow access to the seat control module retaining screw. 5. Remove the seat control module retaining screw. 6. Disconnect the electrical connectors from the seat control module as necessary. 7. Remove the seat control module from the seat assembly. INSTALLATION PROCEDURE 1. Align and install the locating tabs on the seat control module with the seat pan. 2. Connect the electrical connectors to the seat control module as necessary. Page 8140 Disclaimer Page 12529 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 6784 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 3514 Registered And Non-Registered Trademarks Part 5 Page 3898 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 1047 For Canada & IPC: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. PARTS INFORMATION Parts Pre-Ship Information - For US and Canada Important: An initial supply of windshield wiper transmission seal assemblies required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of June 28, 2004 and will be approximately 20% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. CUSTOMER REIMBURSEMENT - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Product Recall Customer Reimbursement Procedure Form is included with the customer letter. IMPORTANT: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. CUSTOMER REIMBURSEMENT - For Canada Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted by July 31, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. IMPORTANT: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period Page 12886 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 3895 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 582 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 10278 Speaker: Diagrams Speaker - LF Door Page 13629 Headlamp Switch C1 Part 2 Page 9120 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 2227 Fuse Block - Rear C4 Part 3 Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Only if necessary remove the fuel tank shield. IMPORTANT: Due to an access hole in the fuel tank shield, removal of the shield should not be necessary to access the fuel pressure service connection. 3. Remove the fuel pressure service connection cap, located near the fuel filter. 4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Turn ON the ignition. 6. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 8. Command the fuel pump ON with a scan tool. 9. Close the bleed valve on the fuel pressure gage. 10. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. Page 9302 Lock Cylinder Switch: Description and Operation IGNITION LOCK CYLINDER CASE, INCLUDING THE PASSLOCK(TM) SENSOR The ignition lock cylinder fits inside the ignition lock cylinder case and operates the ignition switch when turned by a key with the proper mechanical cut. When the ignition key is used to turn the ignition lock cylinder to crank, start, a magnet on the lock cylinder passes close to the Passlock(TM) Sensor within the ignition lock cylinder case. The magnet activates the Security Hall Effect Sensor in the Passlock(TM) Sensor which completes a circuit from the security sensor signal circuit through a resistor to the security sensor low reference circuit. The resistance value will vary from vehicle to vehicle. If a magnet from outside of the ignition lock cylinder case is used to attempt to steal the vehicle, the Tamper Hall Effect Sensor will be activated. This completes a circuit from the security sensor signal circuit through a tamper resistor to the security sensor low reference circuit bypassing the security resistor. If the ignition switch is forced to rotate without the correct key, or if the ignition lock cylinder is removed by force, the Passlock(TM) Sensor will be damaged and will not operate. Page 11711 2. Release the clips that retain the garnish molding to the liftgate. 3. Remove the wire harness (1) from the slot located on the garnish molding. 4. Remove the garnish molding from the liftgate. INSTALLATION PROCEDURE 1. Position the garnish molding to the liftgate. 2. Install wire harness (1) into the slot located on the garnish molding. 3. Index the locating tabs to the corresponding holes in the liftgate. 4. Index the retaining clips to the liftgate. 5. Push the garnish molding into the liftgate in order to fully seat the retaining clips. 6. Close the liftgate. Garnish Molding Replacement - Windshield Pillar GARNISH MOLDING REPLACEMENT - WINDSHIELD PILLAR REMOVAL PROCEDURE Page 4089 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 1512 For vehicles repaired under warranty, use the table. Disclaimer Locations Electronic Components Page 4361 Powertrain Control Module (PCM) C2 Part 5 Page 3615 Engine Coolant Temperature (ECT) Sensor Page 7898 1. Install the stabilizer shaft link and the washer to the lower control arm. 2. Install the stabilizer shaft link to lower control arm retaining nut. 3. Install the stabilizer shaft link to the stabilizer shah. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the stabilizer shaft link to stabilizer shaft retaining nut. Tighten the stabilizer shaft retaining nuts to 100 Nm (74 ft. lbs.). 5. Lower the vehicle. Page 1722 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 7219 Page 6707 Registered And Non-Registered Trademarks Part 3 Page 8828 Cabin Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2 wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and low reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0-5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the following conditions: The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 6751 Knock Sensor (KS) 1 Front Knock Sensor (KS) 1 Front Page 3654 Manifold Absolute Pressure (MAP) Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 3. Press the retainer locking tabs inward, then pull the retainer (1) up to remove it. 4. Remove the MAP sensor (2). 5. Inspect the MAP sensor seal for damage, and replace as necessary. INSTALLATION PROCEDURE Page 4925 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Page 7235 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Locations Electronic Components Page 4131 Abbreviations And Meanings Part 17 Page 13004 Abbreviations And Meanings Part 5 Page 1718 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 12311 Sunroof Module C2 Page 10129 Page 3027 During the 2004 model year, there was a design change made to the engine oil pick up tube and the front cover as shown. The first design parts used in production for 2002, 2003 and part of 2004 model year used an 0-ring type seal between the pick up tube and the front cover. The second design parts began production during the 2004 model year and use a face type seal. Anytime the front cover or oil pick up tube are being serviced, be sure to identify which design is being serviced. The correct pick up tube must be used with its corresponding front cover or an engine failure could result. Any vehicle requiring a new front cover must be serviced with the second design front cover, therefore, the engine oil pick up tube must be replaced at the same time. Disclaimer Page 7460 C101 Part 4 Page 6436 20. Wait approximately 30 seconds, and then inspect the new left front brake pipe and fittings for leaks. Any brake leaks identified must be repaired prior to completing this bleed procedure. 21. Install a proper size box-end wrench onto the left front wheel hydraulic circuit bleeder valve (screw) located on the caliper. 22. Install a transparent hose over the end of the bleeder valve. 23. Submerge the open end of the transparent hose into a transparent container partially filled with DOT-3 brake fluid from a clean, sealed brake fluid container. 24. Loosen the bleeder valve to purge the air from the left front wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, and then tighten the bleeder valve. 25. Close the J 29532, or equivalent, fluid tank valve, and then disconnect the J 29532, or equivalent, form the J 35589-A. 26. Remove the J 35589-A from the brake master cylinder reservoir. 27. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 28. Connect a Tech 2 to the vehicle's diagnostic link connector (DLC) and perform the automatic bleed procedure. 29. After completion of the automatic bleed procedure, slowly depress the brake fluid and verify that it feels firm. Release the pedal. 30. Verify that the fluid in the master cylinder reservoir is at the maximum-fill level. 31. Install the GM Recall Identification Label. Page 7672 Lighting - Turn Signal Flasher Sticks ON Turn Signal Flasher: Customer Interest Lighting - Turn Signal Flasher Sticks ON Bulletin No.: 03-08-42-014 Date: December 09, 2003 INFORMATION Subject: New Turn Signal Flasher Module Availability Models: 2004 Buick Rainier 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet SSR - Built Prior to VIN Breakpoint 3B101657 2003-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2003-2004 Oldsmobile Bravada Built After April 2003 New Flasher Module Availability Important: Always use the part number listed in the table below for flasher replacement on the above vehicles. The factory installed Turn Signal Flasher Module in the vehicles listed above has been superseded by a revised part number. Do not use the original flasher module part number if a replacement is needed. An anomaly has been observed in the original production flasher that could cause the flasher module to stick in the "on" position if the directional signal is used for an extended period of time. Always use the part number listed in the table below for flasher replacement on the above vehicles. Parts Information Parts are currently available from GMSPO. Disclaimer Page 12959 Page 1022 40.6. Install the ring terminal (orange wire) to the underhood fuse block stud (1). 40.7. Locate circuit no. 241 or 441 (ignition 3 brown wire) (PIN B11 or C11) in the existing underhood fuse block harness (1) of C2 (2) and splice bare wire to it using a splice clip. Wrap with electrical tape. 40.8. Locate connector C105 (3), located on the left side inner fender. Separate the connector halves. On the female side of the connector, remove the terminal from cavity F (gray/black wire) and tape back. 40.9. Install the terminal end on the pump wiring harness into cavity F of connector C105. 41. Install the evaporator tube and nut to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 42. Install the coolant recovery reservoir with the accumulator attached. 43. Install the nut and bolt securing the coolant recovery reservoir. 44. Install the coolant hoses to the coolant recovery reservoir. 45. Install the nut retaining the accumulator to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 46. Install the compressor suction hose assembly to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). Page 12990 Conversion - English/Metric Part 1 Page 2555 Cylinder Liner: Service and Repair The content of this article reflects the changes identified in TSB 04-06-01-022B Bulletin No. 04-06-01-022B Date: October 24, 2005 SERVICE MANUAL UPDATE Subject: New Cylinder Bore Piston Sleeve Replacement Procedure Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet Trailblazer 2004-2006 Chevrolet Colorado 2002-2006 GMC Envoy 2004-2006 GMC Canyon 2002-2004 Oldsmobile Bravada with 2.8L, 3.5L or 4.2L Engine (VINs 8, 6, 5 - RPOs LK5, L52, LL8) Cylinder Bore Sleeve Removal Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. Note: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur. 1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore. 2. Install the cylinder bore sleeve puller EN 45680-402 (1), which is part of EN 45680-400, through the cylinder bore. Note: Ensure that the shoe is flat against the bottom of the cylinder bore sleeve or damage to the cylinder bore sleeve puller EN 45680402 will occur. Page 11425 Trunk / Liftgate Shock / Support: Service and Repair Strut Replacement - Liftgate Window Strut Replacement - Lift Gate Window Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open and support the liftgate window. Notice: Refer to Liftgate/Hood Assist Rod Notice in Service Precautions. 2. Lift up the retainer clips on the liftgate window struts using a small flat-bladed tool. 3. Remove the upper end of the liftgate window struts from the ball joint. 4. Remove the lower end of the liftgate window struts from the ball joint. 5. Remove the liftgate window struts from the liftgate window. Installation Procedure 1. Position the liftgate window struts to the liftgate window. 2. Install the upper end of the liftgate window struts to the ball joint. Press in to place until fully seated. 3. Install the lower end of the liftgate window struts to the ball joint. Press in to place until fully seated. 4. Remove the support device from the liftgate window. 5. Close the liftgate window. Procedures Power Door Lock Actuator: Procedures Lock Actuator Replacement - Front Door LOCK ACTUATOR REPLACEMENT - FRONT DOOR REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the door latch assembly. 4. Remove the 2 screws that retain the actuator (1) to the lock. 5. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. 6. Remove the actuator from the latch. INSTALLATION PROCEDURE Locations Body Front End Page 10348 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 10157 Page 1829 Alignment: Service and Repair Wheel Alignment Measuring Procedures Inspection and Preparation Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Irregular or premature wear ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. ^ Inspect the vehicle trim height. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Alignment Angle Measurement Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Page 10325 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 3524 Body Control Module (BCM) C3 Part 3 Page 7899 Stabilizer Link: Service and Repair Rear Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft link retaining nuts. Notice: Do not pry on the stabilizer shaft link. Use care when removing or installing the stabilizer shaft link in order to avoid tearing or puncturing the stabilizer shaft link boot. Damage to the stabilizer shaft link boot will lead to damage to the stabilizer shaft link. 3. Disconnect the stabilizer shaft link from the frame. 4. Disconnect the stabilizer shaft link from the stabilizer shaft and remove the stabilizer shaft link. Installation Procedure 1. Connect the stabilizer shaft link to the stabilizer shaft and to the frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the stabilizer shaft link retaining nuts. Tighten the stabilizer shaft nuts to 100 Nm (74 ft. lbs.). 3. Lower the vehicle. Service and Repair Horn Switch: Service and Repair Horn Switch Replacement Removal Procedure Caution: Refer to Servicing the SIR System Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the Inflatable Restraint Steering Wheel module. 3. Remove the horn plunger from the steering column by pressing inward to the stop and rotating horn plunger 90 degrees. 4. Disconnect the horn contact plate:(2) captured screws (1, 4) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure Page 13911 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 7195 Disclaimer Page 1752 Abbreviations And Meanings Part 16 Page 7557 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 13885 Page 10857 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 7360 Fuse Block - Underhood C4 Part 3 Page 12631 Seat Adjuster Switch - Passenger (w/Heat) Part 1 Page 2228 Fuse Block - Rear C4 Part 4 Fuse Block - Underhood C1 Fuse Block - Underhood C1 Part 1 Camshaft Actuator System Camshaft Position Sensor: Description and Operation Camshaft Actuator System CAMSHAFT POSITION (CMP) ACTUATOR SYSTEM The Camshaft Position Actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation control, a wider engine torque range, improved gas millage, and improved engine idle stability. The CMP Actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. CMP ACTUATOR SYSTEM OPERATION The CMP Actuator system is controlled by the Powertrain Control Module (PCM). The PCM sends a pulse width modulated 12 volt signal to a Camshaft Position (CMP) Actuator Solenoid in order to control the amount of engine oil flow to a cam Phaser passage. There are two different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The Cam Phaser is attached to a camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position. Engine oil pressure, viscosity, temperature and engine oil level can have an adverse affect on cam phaser performance. The PCM calculates the optimum cam position through the following inputs: Engine Speed - Manifold Absolute Pressure (MAP) - Throttle Position (TP) Indicated Angle - Crankshaft Position (CKP) - Camshaft Position (CMP) - Engine Load. - Barometric (BARO) Pressure The Cam Phaser default position is 0 degrees. The PCM uses the following inputs before assuming control of the cam phaser: Engine Coolant Temperature (ECT) - Closed Loop Fuel Control - Engine Oil Temperature - Engine Oil Pressure - Engine Oil Level - CMP Actuator Solenoid circuit state - Ignition 1 signal voltage - Barometric (BARO) Pressure CMP ACTUATOR SOLENOID CIRCUIT DIAGNOSTICS The PCM monitors the control circuits of the CMP Actuator Solenoid for electrical faults. The PCM has the ability to determine if a control circuit is open, shorted high, and shorted low. If the PCM detects a fault with a CMP Actuator Solenoid circuit a Diagnostic Trouble Code (DTC) will set. CMP ACTUATOR SYSTEM PERFORMANCE DIAGNOSTICS The PCM monitors the performance of the CMP Actuator system by monitoring the actual and desired positions of a cam phaser. If the difference between the actual and desired position is more than a calibrated angle for more than a calibrated amount of time, a DTC will set. Page 1023 47. Connect the electrical connector to the A/C low pressure switch. 48. Install the lower air cleaner housing/washer solvent tank assembly onto the mounting studs. 49. Install the two air cleaner housing/washer tank assembly retaining nuts to the mounting studs. 50. Connect the washer pump hoses. 51. Connect the washer solvent tank electrical and install wiring harness to the retaining clips. 52. Install the air inlet duct to the lower air cleaner housing/washer solvent tank assembly. 53. Install the air cleaner filter element and air outlet duct. 54. Install the air cleaner cover. 55. Install the tender rear upper brace. 56. Connect the negative battery cable. 57. Recharge the refrigerant system. 58. Fill the cooling system. 59. Inspect the cooling system for leaks. 60. Leak test the refrigerant fittings using J 39400-A. Parts Information Warranty Information Page 12508 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 6918 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 7374 Location View Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 5124 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON(R) transmission fluid. Page 12968 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 9124 Page 12075 WA8624/50 - WA8624/50 Page 7980 Suspension Strut / Shock Absorber: Specifications Front Shock Absorber Retaining Nut 33 ft. lbs. Shock Module Upper Retaining Nuts 33 ft. lbs. Shock Module Yoke to the Lower Control Arm Retaining Nut 81 ft. lbs. Shock Module Yoke to the Shock Absorber Pinch Bolt 52 ft. lbs. Rear Shock Absorber Lower Mounting Bolt 52 ft. lbs. Shock Absorber Upper Mounting Bolt 59 ft. lbs. Page 5633 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Page 12083 WA9792/39 - WA990A/19U Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This Page 12856 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 4048 Powertrain Control Module (PCM) C3 Part 4 Specifications Coolant Outlet: Specifications Water Outlet Housing Bolts ................................................................................................................. ....................................................... 10 Nm (89 lb in) Fuse Block - Rear (Long Wheelbase) Fuse Block: Application and ID Fuse Block - Rear (Long Wheelbase) Location View Page 10648 Page 4238 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 6942 Application Table Part 3 Page 6775 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 6228 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Specifications Brake Pad: Specifications Pad minimum thickness See Note Replace the disc brake pads when the friction surface is worn to within 0.76 mm (0.030 inch) of the mounting plates. Page 12881 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 4417 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor (1) from the air duct with a twisting and pulling motion. INSTALLATION PROCEDURE 1. Install the IAT sensor (1) to the air duct with a pushing and twisting motion. 2. Reconnect the IAT sensor electrical connector. Page 3474 Conversion - English/Metric Part 1 Page 7943 ^ The LH and RH springs are not necessarily the same part numbers. ^ Each vehicle may have a different build combination. ^ Use the RPO label located in the glove box to determine what part number springs to replace. ^ Only small quantity of parts are available. Please DO NOT order for stock only. 1. Select the correct new rear coil spring part numbers. Refer to the Parts Information below. 2. Install the upper bushing seats on the new rear coil springs and install the springs into the vehicle. 3. Raise the rear axle with the adjustable jack stand. 4. Install the two shock absorber lower mounting bolts. Tighten Tighten the two shock absorber lower mounting bolts to 80 N.m (59 lb-ft). 5. Remove both of the adjustable jack stands from under the vehicle. 6. Lower the vehicle. Parts Information Warranty Information Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 9851 3. Install the 3 retaining screws to the garage door opener. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 0.8 N.m (7 lb in). 4. Connect the electrical connector to the garage door opener (3). 5. Install the overhead console. Front Stabilizer Link: Service and Repair Front Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft link to stabilizer shaft retaining nut. 3. Remove the stabilizer shaft link to lower control arm retaining nut. Notice: Do not pry on the stabilizer shaft link. Use care when removing or installing the stabilizer shaft link in order to avoid tearing or puncturing the stabilizer shaft link boot. Damage to the stabilizer shaft link boot will lead to damage to the stabilizer shaft link. 4. Remove the stabilizer shaft link and washer. Installation Procedure Important: There is a washer between the stabilizer shaft link and the lower control arm made of hardened steel and has a felt inner liner. Only replace this washer with an identical washer, standard washers should not be used. Page 5451 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Page 4112 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 8381 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Engine Controls - Underhood Ticking Noise Fan Clutch: Customer Interest Engine Controls - Underhood Ticking Noise Bulletin No.: 05-06-02-004 Date: April 06, 2005 TECHNICAL Subject: Underhood Tick Noise at Idle (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada Condition Some customers may comment on an underhood tick noise heard while the vehicle is idling. Technicians may find that the noise does not increase or decrease with changes in the engine idle RPM. The tick noise occurs at approximately one second intervals. Cause This condition may be caused by the electro-viscous fan clutch control function of the Powertrain Control Module (PCM) attempting to keep the fan speed between 300-600 revolutions per minute (RPM). At idle, the cooling fan speed will drag to approximately 500 RPM then oscillate between 300 and 600 RPM. When the fan speed drops below 500 RPM, the PCM will pulse the fan control solenoid. The pulsing of the solenoid is the cause of the ticking noise. Correction Technicians are to verify that the cooling fan clutch is the source of the noise by using either one of the following two methods: ^ Use a Tech 2(R) to command the cooling fan off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. ^ The cooling fan clutch electrical connector, located on the cooling fan shroud, may be disconnected with the engine off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. Be sure to clear any Diagnostic Trouble Codes (DTCs) that may have set while the cooling fan clutch is disconnected. Technicians are to reprogram the PCM with an updated software calibration. The new software calibration is currently available in TIS for all the vehicles listed above. Warranty Information Page 13009 Abbreviations And Meanings Part 10 Page 6616 Negative: Service and Repair Battery Negative Cable Replacement REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the bolt that secures the harness to the front wheelhouse panel (1). 3. Remove the bolt that secures the harness to the shock tower (2). 4. Remove the harness from the engine harness bracket. 5. Remove the bolt that secures the harness to the engine block. INSTALLATION PROCEDURE IMPORTANT: The negative battery cable must not be connected to the battery prior to the installation of the engine harness ground terminal to the engine block. - The negative battery cable must not be connected to the battery prior to the installation of the instrument panel harness and the engine harness to the powertrain control module. 1. Clip the harness to the engine harness bracket. 2. Install the bolt that secures the harness to the shock tower (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 10 N.m (89 lb in). 3. Install the bolt that secures the harness to the engine block. Tighten Page 3814 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada C100 - C118 Multiple Junction Connector: Diagrams C100 - C118 C100 Part 1 Page 9970 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 12925 Abbreviations And Meanings Part 14 Page 13087 Page 2561 ^ EN 45680-412 Set Gage Ring (2) ^ EN 45680-413 Metal Shavings Catch Plug (3) ^ EN 45680-866 Drive Adapter (4) ^ EN 45680-414 Bolts (5) 1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange. 2. Place metal shaving catch plug EN 45680-413 into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-413 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. 3. Place additional metal shaving catch plugs EN 45680-413 into all remaining cylinder bore sleeves. 4. Ensure that the metal shaving catch plug EN 45680-413 is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. Page 12903 Conversion - English/Metric Part 2 Page 4297 Registered And Non-Registered Trademarks Part 5 Description and Operation Fuel Pressure Regulator: Description and Operation FUEL PRESSURE REGULATOR ASSEMBLY Fuel Pressure Regulator Assembly The fuel pressure regulator is a diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure on the other side. The fuel pressure regulator maintains a constant pressure differential across the fuel injectors under all operating conditions. The fuel pressure regulator compensates for engine load by increasing fuel pressure as the engine vacuum drops. Page 6250 9. Install the brake caliper assembly. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Caution: Refer to Firm Brake Pedal Caution in Service Precautions. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 12. Pump the brake pedal slowly and firmly in order to seat the brake pads. Rear Brake Caliper Bracket Replacement- Rear Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Inspect the brake caliper assembly. Notice: Support the brake caliper with heavy mechanics wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 4. Remove the rear brake caliper assembly, relocate the brake caliper to the side. 5. Inspect the brake pads. Page 8204 HVAC Module-Auxiliary (Body Type VIN 6) Service and Repair Trunk / Liftgate Interior Trim Panel: Service and Repair Trim Panel Replacement - Lift Gate Removal Procedure 1. Open the liftgate window. 2. Remove the push-pin retainer from the trim panel. 3. Close the liftgate window. 4. Open the liftgate. 5. Remove the screw that retains the pullstrap to the liftgate trim panel. 6. Remove the pullstrap from the liftgate trim panel. 7. Use a flat-bladed tool in order to carefully release the trim panel retainers. 8. Remove the trim panel from the liftgate. Installation Procedure 1. Install the trim panel to the liftgate. 2. Ensure that the trim panel retainers are fully seated. 3. Install the pullstrap to the trim panel. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screw that retains the pullstrap to the trim panel. Tighten the pullstrap screw to 4 N.m (35 lb in). C100 - C118 Multiple Junction Connector: Diagrams C100 - C118 C100 Part 1 Page 6658 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 12961 Page 8360 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 7856 Cross-Member: Service and Repair Steering Gear Crossmember Replacement - Rear Steering Gear Crossmember Replacement - Rear Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the front steering gear crossmember rear mounting bolts. 3. Remove the rear steering gear crossmember mounting bolts. 4. Remove the rear steering gear crossmember from the vehicle. Installation Procedure 1. Install the rear steering gear crossmember to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear steering gear crossmember mounting bolts. Tighten the rear steering gear crossmember mounting bolts to 50 N.m (37 lb ft). 3. Install the front steering gear crossmember rear mounting bolts. Tighten the rear steering gear crossmember mounting bolts to 50 N.m (37 lb ft). 4. Lower the vehicle. Page 1309 Ambient Light Sensor (With RPO Code CJ3) Page 13490 Disclaimer Page 5869 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 Page 7497 Multiple Junction Connector: Diagrams C401 - C901 C401 (Body Type VIN 6) Part 1 Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the protective cover from the underhood fuse block. 2. Remove the compressor relay (1) from the underhood fuse block (2). INSTALLATION PROCEDURE 1. Install the compressor relay (1) to the underhood fuse block (2). 2. Install the protective hood to the underhood fuse block. Page 7081 C101 Part 4 Page 10524 Service and Repair Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Page 10126 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 12955 Page 262 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Recall - Rear Side Door Latch Corrosion Technical Service Bulletin # 05077 Date: 060216 Recall - Rear Side Door Latch Corrosion Bulletin No.: 05077 Date: February 16, 2006 SAFETY Subject: 05077- REAR SIDE DOOR CLOSURE Models: 2002-2003 CHEVROLET TRAILBLAZER EXT 2002-2003 GMC ENVOY XL LOCATED IN CORROSION AREAS Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002-2003 Chevrolet TrailBlazer EXT and GMC Envoy XL vehicles that have ever been registered in corrosion areas. The rear side doors on these vehicles may not latch or may not unlatch properly due to corrosion caused by road splash, such as water and road salt. Depending on the location of the corrosion in the latch, the door may either be difficult to open from the inside or outside, or may bounce back when the door is swung shut from the outside. The driver information center may or may not indicate that the door is ajar. If the door is not latched properly and it goes unnoticed, it may open while the vehicle is in motion. If the occupant is unbelted, they may fall out of the vehicle and personal injury could occur. Correction Dealers are to install a seal to prevent water intrusion into the latch. The latch is also to be inspected and replaced, if necessary. Vehicles Involved Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 10892 Registered And Non-Registered Trademarks Part 2 Page 7008 6. Connect the mobile telephone harness connector (1) to the junction block. 7. Connect the instrument panel harness connector (1) to the block base. 8. Install the junction block to the block base. Ensure that the retaining tabs are fully seated. Page 2196 Application Table Part 3 Location View Page 13896 Page 6842 Page 9882 3. Install the screw that retains the seat control module to the seat pan. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat module screw to 3 N.m (26 lb in). 4. Install the seat pan to the seat assembly. 5. Install the nuts which retain the seat pan to the seat assembly. Tighten Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 6. Install the 3 seat switch bezel screws. Page 620 Registered And Non-Registered Trademarks Part 6 Page 7771 For vehicles repaired under warranty, use the table. Disclaimer Page 4310 Door Control Module Diagram 2 Page 1099 Switch Replacement - Door Lock and Side Window - Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. 4. If replacing the passenger door module, program the passenger door module. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. IMPORTANT: When replacing the passenger door module, the set up procedure must be performed. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 9493 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 12921 Abbreviations And Meanings Part 10 Description and Operation Compass: Description and Operation COMPASS The mirror uses two magnetic field sensors for compass direction. One sensor is for north and south, the other is for east and west. The mirror supplies a signal and low reference to each sensor. As the vehicle travels with or against the earth's magnetic pull, there will be a change in voltage on one or both sensors. As a result of the change in voltage, the mirror changes the heading on the compass display. Page 8827 Instrument Panel Carrier-Air Duct B-Pillar, Left Page 13082 Page 13153 Abbreviations And Meanings Part 25 Specifications Oil Level Sensor: Specifications Oil Level Sensor Bolt 89 inch lbs. Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: Customer Interest Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Page 3302 7. Remove the heater outlet hose (7) from the outlet hose fitting. 8. Remove the heater outlet hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185. 4. Install the heater outlet hose (3) to the heater core (1). 5. Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Install the transmission. 7. Install the generator. 8. Fill the cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. With RPO Code LM4 HEATER HOSE REPLACEMENT - OUTLET (WITH RPO CODE LM4) See: Application and ID/RPO Codes TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the coolant bypass valve. 2. Remove the transmission. Page 4358 Powertrain Control Module (PCM) C2 Part 2 Page 1130 Seat Adjuster Switch - Passenger (w/Heat) Part 2 Page 9784 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 1389 Crankshaft Position (CKP) Sensor Locations Rear Window Wiper/Washer Switch (Chevrolet) Page 12947 Brake Warning Indicator: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Hydraulic System Testing and Inspection. Page 7149 Application Table Part 2 Page 4072 Page 5274 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7120 C500 Part 1 Page 10530 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 4911 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Locations Instrument Panel Page 6919 Auxiliary Power Outlet: Connector Views Auxiliary Power Outlet - Console Page 12848 Abbreviations And Meanings Part 25 Page 7697 6. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 7. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 8. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 9. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. 10. Install the SIR fuse to the fuse block (1) located in the underhood electrical center. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition. Page 9637 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 5750 13. Install the TCC solenoid bolts. ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.) 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Page 1153 Sunroof Switch Page 13272 Abbreviations And Meanings Part 10 Page 11812 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 3723 For vehicles repaired under warranty, use the table. Disclaimer Page 6025 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Locations Engine Page 2266 7. Remove the junction block bracket retaining bolts (1) and remove the junction block bracket from the vehicle. INSTALLATION PROCEDURE 1. Position the junction block bracket and install the bolts (1). Tighten Tighten the junction block bracket bolts to 6 N.m (53 lb in). 2. Align the wiring harnesses and install the fuse relay center. 3. Install the fuse relay center bolts (3). Tighten Tighten the relay center bolts to 6 N.m (53 lb in). Page 7354 Fuse Block - Underhood C2 Part 5 Page 7694 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module yellow 4-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 1. Remove the key from the ignition. Page 13191 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 4. Connect the IP module yellow 4-way connector (1) located behind the IP support. 5. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. Page 6453 1. Install EBCM (2) onto BPMV (3). Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. 2. Install the four EBCM bolts. ^ Tighten the four bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM (2). 4. Install BPMV (3) to EHCU bracket (5). 5. Connect the two electrical harness connectors to the EBCM (2). Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. 6. Install the 5 brake pipes to the BPMV (3). ^ Tighten the brake pipe fittings to 30 Nm (22 ft. lbs.). 7. Bleed the brake system. Page 12821 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 10154 Page 6863 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 7894 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 840 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 2021 block. 3. Position the inlet heater hose clamp (1) at the engine block using J 38185. 4. Install the quick connect end of the outlet heater core hose (2) to the heater core. 5. Fill the engine cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. Body VIN 6 / GMT 370 HEATER HOSE REPLACEMENT - INLET (BODY TYPE VIN 6) TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6) in Cooling System. 2. Remove the coolant recovery reservoir. 3. Using the J 43181 disconnect the inlet heater hose (2) from the heater core inlet tube. 3.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 3.2. Close the tool around the inlet heater core hose. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 4. Reposition the hose clamp at the engine outlet using J 38185. 5. Remove the heater inlet hose (4) from the the engine block. 6. Remove the nut retaining the coolant bypass valve to the cowl. 7. Remove the heater inlet hose. INSTALLATION PROCEDURE Specifications Engine Mount: Specifications Engine Front Lift Bracket Bolt 37 ft. lbs. Engine Harness Bracket Bolt 37 ft. lbs. Engine Mount Bracket Bolt (engine) 37 ft. lbs. Engine Mount Bracket Bolt (frame) 81 ft. lbs. Engine Mount Nuts (upper and lower) 52 ft. lbs. Page 6855 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Description and Operation Clockspring Assembly / Spiral Cable: Description and Operation INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module coil consists of two or more current-carrying coils. The coils allow the rotation of the steering wheel while maintaining continuous electrical contact between the driver deployment loop and the steering wheel module. Two or four (if equipped with dual stage air bags) coil wires are used for the steering wheel module deployment loop. Additional coil wires are used for accessories attached to the steering wheel depending on the vehicle model. The steering wheel module coil connector is located near the base of the steering column. The connector contains a shorting bar that shorts the steering wheel module coil deployment loop circuitry to prevent unwanted deployment of the air bag when servicing the inflator module. Service and Repair Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the harness electrical connector (2) from the evaporative emission (EVAP) canister purge valve (1). 3. Disconnect the EVAP purge pipe from the EVAP canister purge valve. 4. Disconnect the engine vacuum pipe from the EVAP canister purge valve. 5. Remove the purge valve (2) from the purge valve mounting bracket. 6. If replacing the purge valve bracket, remove the attaching bolt (1) and purge valve bracket. INSTALLATION PROCEDURE Page 9437 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 9758 Garage Door Opener Component Views Page 9394 Registered And Non-Registered Trademarks Part 2 Page 13242 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 4771 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. 2. Install the APP sensor retaining fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 4174 Steps 23-29 The numbers below refer to the step numbers on the diagnostic table. 2. A partial malfunction in the class 2 serial data circuit uses a different procedure from a total malfunction of the class 2 serial data circuit. The following modules communicate on the class 2 serial data circuit: 3. The following DTCs may be retrieved with a history status, but are not the cause of the present condition. Page 333 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 13137 Abbreviations And Meanings Part 9 Page 831 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 4100 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 7287 Abbreviations And Meanings Part 23 Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Weatherstrip Replacement - Auxiliary Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Page 475 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 13282 Abbreviations And Meanings Part 20 Page 192 Locations Instrument Harness, Instrument Panel Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: Customer Interest Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 4311 Door Control Module Diagram 3 Page 11819 Abbreviations And Meanings Part 4 Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Page 2258 Location View Page 546 CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. The scan tool instructs you to perform the following items: - Accelerate to wide open throttle (WOT). - Release the throttle when fuel cut-off occurs. - Observe the fuel cut-off for the engine that you are performing the learn procedure on. - The engine should not accelerate beyond calibrated RPM value. - Release the throttle immediately if value is exceeded. - Block the drive wheels. - Set the parking brake. - DO NOT apply the brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn the A/C OFF. - The vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. With the scan tool, enable the crankshaft position system variation learn procedure. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release the throttle when the fuel cut-off occurs. 8. The scan tool displays Learn Status-Learned this ignition: - If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. - If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. - If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The crankshaft position system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P1336 sets: Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - Crankshaft position sensor replacement - Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Page 435 Page 373 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 13286 Abbreviations And Meanings Part 24 Service and Repair Rear Fender Liner: Service and Repair Wheelhouse Panel Replacement Removal Procedure 1. Remove the bolt that retains the wheelhouse panel to the rocker panel molding. 2. Remove the 2 screws that retain the wheelhouse panel to the rear fascia. 3. Remove the 4 push-pins retaining the wheelhouse panel to the wheelhouse. 4. Remove the wheelhouse panel from the vehicle. Installation Procedure 1. Install the wheelhouse panel to the vehicle. 2. Install the 4 push-pins retaining the panel to the wheelhouse. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 2 screws that retain the wheelhouse panel to the rear fascia. Tighten the 2 screw to 2 N.m(18 lb in). 4. Install the bolt that retains the wheelhouse panel to the rocker panel molding. Tighten the bolt to 7 N.m(62 lb in). Page 4879 Parts are currently available from GMSPO. Disclaimer Page 9974 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 12474 8. Install the push pins (1) on the underside of the seat bottom. 9. Install the latch bezels. 10. Install the seat cushion bracket. 11. Install the seat cushion in the vehicle. Seat Cushion Cover and Pad Replacement - Rear No. 1 (TrailBlazer EXT, Envoy XL) Seat Cushion Cover and Pad Replacement - Rear No. 1 (Trailblazer EXT, Envoy XL) Tools Required J 36796Clip Removal Tool Removal Procedure 1. Release the J-strips that retain the cover to the seat pan. 2. Compress the foam and partially remove the seat cover assembly from the seat pan. Important: When separating the seat cover retaining strips, do not pull the adhesive-backed strip from the seat pad. 3. Remove the cover from the cushion by separating the retaining strips. 4. Separate and remove the cushion and cover assembly from the seat pan. 5. Release the reinforcement bar from the hog-rings. 6. Remove the cover from the cushion. Installation Procedure 1. Install the cover to the cushion. 2. Install the reinforcement bar to the hog-rings. 3. Attach the retaining strips that retain the cover to the cushion. 4. In order to install the seat cushion to the seat pan, perform the following: 5. Install the seat pan to the cushion and cover assembly. 6. Compress the foam and install the seat cover and cushion to the seat pan. Page 3010 5. Remove the top chain guide bolts. 6. Remove the top chain guide. 7. Remove the exhaust camshaft position actuator bolt. 8. Remove the exhaust camshaft position actuator. 9. Remove the intake camshaft sprocket bolt. 10. Remove the intake camshaft sprocket. 11. Remove the timing chain. 12. Remove the crankshaft sprocket. 13. Remove the cylinder head access hole plugs. Page 7585 For vehicles repaired under warranty, use the table. Disclaimer Page 2617 7. Remove the camshafts. Important: Once removed, place the valve rocker arms and valve lash adjusters in an organized order so the components can be installed into the original locations. 8. Remove the valve rocker arms. 9. Remove the valve lash adjusters. Installation Procedure Page 10869 Abbreviations And Meanings Part 5 Page 1268 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Page 10908 Door Control Module Diagram 2 Page 2947 Abbreviations And Meanings Part 19 Page 13021 Abbreviations And Meanings Part 22 Page 11292 Hood Latch: Service and Repair Hood Latch Support Replacement Hood Latch Support Replacement Removal Procedure 1. Remove the radiator air intake baffle. 2. Remove the headlamp housing panel. 3. Remove the hood latch. 4. Remove the bolts that retain the hood latch support to the radiator support. 5. Remove the hood latch support from the vehicle. Installation Procedure 1. Install the hood latch support to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the hood latch support to the radiator support. Tighten the bolts to 20 N.m (15 lb ft). 3. Install the hood latch. 4. Install the headlamp housing panel. 5. Install the radiator air intake baffle. Page 5287 Disclaimer HVAC System - Automatic Air Door Actuator / Motor: Diagrams HVAC System - Automatic Air Temperature Actuator-Auxiliary (Body Type VIN 6) Page 1319 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the pushrod retainer (3) from the brake pedal pin (4). 2. Remove the stop lamp switch (1) and the pushrod (2) from the brake pedal pin (4). 3. Disconnect the stoplamp switch (1) electrical connector. 4. Remove the stoplamp switch from the vehicle. INSTALLATION PROCEDURE 1. Install the electrical connector to the stop lamp switch (1). 2. Position the stop lamp switch (1) on the pushrod (2) and install the assembly on the brake pedal pin. 3. Install the pushrod retainer (3) to the brake pedal pin (4). The retainer will snap into place. Page 7284 Abbreviations And Meanings Part 20 Page 13692 Ambient Light Sensor (With RPO Code CJ3) Page 8899 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 6. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. 5. Access the I/P module connector through the glove box. Page 6970 Fuse Block - Underhood C1 Part 6 Fuse Block - Underhood C2 Page 4572 Disclaimer Page 5995 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12475 7. Connect the J-strips that retain the cover to the seat pan. Seat Cushion Cover and Pad Replacement - Rear No. 2 Seat Cushion Cover and Pad Replacement - Rear No. 2 Removal Procedure 1. Remove the two bolts (2) securing the rear seat cushion assembly (1) to the seat latch rod (3). 2. Remove the rear seat cushion assembly. 3. Remove the pull handle assembly (1). 4. Remove the J-strips (2) securing the rear seat cushion cover to the seat cushion panel. 5. Remove the seat cushion panel from the pad and cover. 6. Remove the hog rings (1) from the seat cover. Page 11473 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Page 12494 Page 9378 Abbreviations And Meanings Part 12 Service and Repair Front Door Exterior Handle: Service and Repair Door Handle Replacement - Front Outside Removal Procedure 1. Close the window to the full up position. 2. Remove the door trim panel. 3. Remove the rear half of the water deflector from the door. 4. Release the upper lock rod retainer (1) from the rod. 5. Remove the lock rod from the handle assembly. 6. Release the lock cylinder rod retainer (2) from the lock rod, if equipped. 7. Remove the lock cylinder rod from the handle assembly, if equipped. 8. Remove the 2 door handle retaining nuts. 9. Remove the handle assembly from the door. 10. Remove the lock cylinder from the handle, if equipped. Installation Procedure 1. Install the lock cylinder to the handle, if equipped. 2. Install the handle assembly to the door. 3. Install the upper lock rod to the handle assembly. 4. Install the lock rod retainer (1). 5. Install the lock cylinder rod to the handle assembly, if equipped. 6. Install the cylinder lock rod retainer (2), if equipped. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the 2 door handle retaining nuts. Tighten the nuts to 10 N.m (88 lb in). 8. Attach the rear half of the water deflector to the door. 9. Install the door trim panel. Page 6870 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 12537 Abbreviations And Meanings Part 5 Page 481 Labor Time Information Locations Body Control Module: Locations Body Wiring Harness Extension Harness Page 11530 Skid Plate: Service and Repair Engine Protection Shield Replacement Engine Protection Shield Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield mounting bolts. 3. Remove the engine shield. Installation Procedure 1. Install the engine shield. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine shield mounting bolts. Tighten the engine shield mounting bolts to 25 N.m (18 lb ft). 3. Lower the vehicle. Page 10622 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 7841 3. Connect the ABS wheel speed sensor wiring harness to the upper control arm. 4. Connect the upper control arm to the steering knuckle 5. Install the upper ball joint to upper control arm pinch bolt and nut. Tighten the upper ball joint to upper control arm pinch bolt to 40 Nm (30 ft. lbs.). 6. Install the tire and wheel. 7. Lower the vehicle. 8. Check the front wheel alignment. Lower Control Arm Replacement Lower Control Arm Replacement Tools Required ^ J24319-B Steering Linkage and Tie Rod Puller ^ J43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. Page 13645 3. Position the license lamp lens to the liftgate. 4. Verify that the license lamp lens gasket is fully seated to the liftgate. 5. Install the 2 license lamp lens retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.4 N.m (12 lb in). Page 9562 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 3035 Variable Valve Timing Solenoid: Service and Repair CAMSHAFT POSITION (CMP) ACTUATOR SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the drive belt. 2. Remove the 3 power steering pump bolts and move the pump out of the way. 3. Disconnect the camshaft position actuator solenoid electrical connector. 4. Remove the camshaft position actuator solenoid retaining bolt (3). 5. Remove the camshaft position actuator solenoid (2) from the engine block. 6. Clean debris from the hole (1). INSTALLATION PROCEDURE 1. Install a new O-ring on the camshaft position actuator solenoid. 2. Lubricate the hole (1) with engine oil. 3. Install the camshaft position actuator solenoid (2) and bolt (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Connect the camshaft position actuator solenoid electrical connector. 5. Install the power steering pump and bolts. 6. Install the drive belt. Page 8085 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 12922 Abbreviations And Meanings Part 11 Page 4829 1. Install the ignition coil (1). IMPORTANT: Make sure that the ignition coil seals are properly seated to the valve cover. 2. Install the ignition coil retaining bolts (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ignition coil retaining bolts to 10 N.m (89 lb in). 3. Replace the ignition coil connectors (1). 4. Install the air cleaner outlet resonator. Page 6248 11. Remove the guide pin seals from the brake caliper mounting bracket. 12. Inspect the brake rotor. Installation Procedure 1. Install the guide pin seals on the mounting bracket. 2. If the guide pins and brake pad retaining clips are to be reused, use denatured alcohol to clean them. 3. Dry the brake guide pins and brake pad retaining clips with non-lubricated, filtered air. 4. Apply high temperature silicone brake lubricant to the brake caliper guide pins. DO NOT apply the lubricant to the brake pad retaining clips. Page 9930 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Only if necessary remove the fuel tank shield. IMPORTANT: Due to an access hole in the fuel tank shield, removal of the shield should not be necessary to access the fuel pressure service connection. 3. Remove the fuel pressure service connection cap, located near the fuel filter. 4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Turn ON the ignition. 6. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 8. Command the fuel pump ON with a scan tool. 9. Close the bleed valve on the fuel pressure gage. 10. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. Page 10098 Disclaimer Page 9570 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 1232 3. Install the sensor (1) to the panel assembly (2). 4. Install the front grille. Page 2963 Oil Pressure Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Lighting - Tail Lamp(s) Inoperative Tail Light Bulb: All Technical Service Bulletins Lighting - Tail Lamp(s) Inoperative Bulletin No.: 03-08-42-006B Date: May 26, 2004 INFORMATION Subject: Tail Lamp Circuit Board Now Available For Service Use Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add a part number. Please discard Corporate Bulletin Number 03-08-42-006A (Section 08 - Body and Accessories). A new tail lamp circuit board is now available for service use. If normal diagnosis of a vehicle leads to a failed tail lamp bulb, inspect the bulb socket to ensure proper fit of the bulb into the socket. If the bulb is found to be loose, or if the circuit board has failed, replace both tail lamp circuit boards with the new part number from GMSPO. Technicians are to replace the tail lamp circuit boards, on both sides of the vehicle, using the following procedure: 1. Remove the tail lamp assembly from the vehicle. 2. Remove the tail lamp circuit board from the tail lamp assembly. 3. Inspect for loose tail lamp bulbs in the tail lamp circuit board. Replace the tail lamp bulb and the tail lamp circuit board if necessary. 4. Install the tail lamp circuit board. 5. Install the tail lamp assembly. 6. Replace the tail lamp circuit board on the opposite side of the vehicle using the above procedure. 7. Verify the operation of the tail lamps. Parts Information Page 11496 License Plate Bracket: Service and Repair License Plate Pocket Replacement Removal Procedure 1. Remove the license pocket lamps. 2. Remove the liftgate trim panel. 3. Disconnect the bellcrank rod from the outside door release handle. 4. Remove the screws that retain the license pocket to the liftgate. 5. Remove the license pocket from the liftgate. Installation Procedure 1. Install the panel to the liftgate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the panel to the liftgate, starting with the bottom center screw first. Tighten the screws to 5 N.m (44 lb in). Page 12272 ^ Place the rear cross rail 50 mm (2 in) from the rear edge of the side rail and push down on the lever to lock it in place. Refer to the illustration above. ^ Inform the customer that this is the proper way to position the cross rail when not in use. Disclaimer Page 4273 Abbreviations And Meanings Part 7 Service and Repair Liftgate Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Window Removal Procedure 1. Open the liftgate window. 2. Pull the liftgate window weatherstrip from the liftgate window opening pinch-weld flange. Installation Procedure 1. Install the liftgate window weatherstrip, starting at the top center of the liftgate window opening position the liftgate window weatherstrip to the pinch-weld flange and working down the right and left sides towards the bottom center, being careful not to stretch the liftgate window weatherstrip while installing it. 2. Install the butt joint seam at the center of the bottom pinch-weld flange. 3. Use a rubber mallet to ensure full engagement of the liftgate window weatherstrip to the pinch-weld flange. 4. Spooning of the liftgate window weatherstrip may be required to complete the installation of the liftgate window weatherstrip. 5. Close the liftgate window. Page 2261 Application Table Part 3 Recall - Flasher Relay Module Replacement Technical Service Bulletin # 05044 Date: 050728 Recall - Flasher Relay Module Replacement Bulletin No.: 05044 Date: July 28, 2005 SAFETY Subject: 05010 - INTERMITTENT INCORRECT TURN SIGNAL OPERATION Models: 2004 BUICK RAINIER 2003-2004 CHEVROLET TRAILBLAZER, TRAILBLAZER EXT 2003-2004 GMC ENVOY, ENVOY XL 2004 GMC ENVOY XUV 2003-2004 OLDSMOBILE BRAVADA Condition General Motors has decided that a detect, which relates to motor vehicle safety, exists in certain 2004 Buick Rainier and GMC Envoy XUV; 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles. Some of these vehicles have an intermittent condition in which the turn signals may not operate as designed. Material build up on the flasher relay may cause the turn signals to flash on both sides of the vehicle when activated similar to hazard warning flashers, or they may illuminate and remain illuminated instead of flashing. The instrument panel would indicate the incorrect operation if this were to occur. Incorrect operation of the turn signal indicator could fail to warn others of the driver's intentions and could lead to a vehicle crash. Correction Dealers are to replace the flasher relay module. Vehicles Involved Page 11782 Door Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Door Sill Plate Replacement - Front Scuff Plate: Service and Repair Door Sill Plate Replacement - Front Door Sill Plate Replacement - Front Removal Procedure 1. If removing the right sill plate, remove the right insulator panel. Refer to Closeout/Insulator Panel Replacement - Right 2. Starting at the rear of the sill plate, use a flat-bladed tool in order to release the 5 retaining tabs. 3. If removing the left sill plate, remove the sill plate from the hood release handle. 4. Remove the sill plate from the door frame. 5. Remove any retaining tabs that remain attached to the door frame. Installation Procedure 1. Ensure that all 5 retaining tabs are securely attached to the sill plate. 2. If installing the left sill plate, position the hood release handle through the sill plate. 3. Align the retaining tabs to the door frame slots. 4. Starting at the front of the sill plate, push down on the sill plate, seating the retaining tabs to the door frame. 5. If installing the right sill plate, install the right insulator panel. Refer to Closeout/Insulator Panel Replacement - Right. Engine Controls - Underhood Ticking Noise PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Underhood Ticking Noise Bulletin No.: 05-06-02-004 Date: April 06, 2005 TECHNICAL Subject: Underhood Tick Noise at Idle (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada Condition Some customers may comment on an underhood tick noise heard while the vehicle is idling. Technicians may find that the noise does not increase or decrease with changes in the engine idle RPM. The tick noise occurs at approximately one second intervals. Cause This condition may be caused by the electro-viscous fan clutch control function of the Powertrain Control Module (PCM) attempting to keep the fan speed between 300-600 revolutions per minute (RPM). At idle, the cooling fan speed will drag to approximately 500 RPM then oscillate between 300 and 600 RPM. When the fan speed drops below 500 RPM, the PCM will pulse the fan control solenoid. The pulsing of the solenoid is the cause of the ticking noise. Correction Technicians are to verify that the cooling fan clutch is the source of the noise by using either one of the following two methods: ^ Use a Tech 2(R) to command the cooling fan off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. ^ The cooling fan clutch electrical connector, located on the cooling fan shroud, may be disconnected with the engine off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. Be sure to clear any Diagnostic Trouble Codes (DTCs) that may have set while the cooling fan clutch is disconnected. Technicians are to reprogram the PCM with an updated software calibration. The new software calibration is currently available in TIS for all the vehicles listed above. Warranty Information Page 4826 Ignition Coil 6 Locations Page 2000 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Page 10649 Page 12807 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 6398 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation. Parts should be ordered on a CSO Customer Special Order. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Ask for Item Number GMP 91 when ordering. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Page 6190 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 7879 Stabilizer Bushing: Service and Repair Rear Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft insulator clamp mounting nut. 3. Remove the stabilizer shaft insulator clamp. 4. Remove the stabilizer shaft insulator from the stabilizer shaft. Installation Procedure 1. Install the stabilizer shaft insulator to the stabilizer shaft. 2. Install the stabilizer shaft insulator clamp. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the stabilizer shaft insulator clamp mounting nut. Tighten the stabilizer shaft insulator clamp mounting nut to 70 Nm (52 ft. lbs.). 4. Lower the vehicle. Page 11969 Disclaimer Page 4092 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Body - Liftgate Glass Unlatches On Bumpy Roads Tailgate Latch: All Technical Service Bulletins Body - Liftgate Glass Unlatches On Bumpy Roads Bulletin No.: 04-08-66-004A Date: June 22, 2004 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Liftgate Glass Unlatches on Rough/Bumpy Road Surfaces (Replace Liftgate Window Latch) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to provide the correction and warranty information, which is now available for Advanced Service Bulletin Number 04-08-66-004. Please discard Corporate Bulletin Number 04-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the rear liftgate window unlatches when driving on rough/bumpy road surfaces. This condition may be very difficult to duplicate. Cause The liftgate window latch may be the cause of this condition. Correction Replace the liftgate window latch. Refer to the Liftgate Window Latch Replacement procedure in the Body Rear End sub-section of the Service Manual. Part Information Parts are expected to be available from GMSPO on June 25, 2004. Warranty Information For vehicles repaired under warranty, use the table. Front Suspension Spring ( Coil / Leaf ): Service and Repair Front "For information regarding this component please refer to shock absorber service and repair" Page 3293 Heater Core: Service and Repair Heater Core Replacement - Auxiliary HEATER CORE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the HVAC module-auxiliary. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove the screws from heater core cover-auxiliary (3) from the HVAC module-auxiliary. 3. Remove the heater core cover-auxiliary (3). 4. Remove the HVAC module pass thru seal-auxiliary. 5. Remove the heater core-auxiliary (2) from the HVAC module-auxiliary. INSTALLATION PROCEDURE 1. Install the heater core-auxiliary (2) to the HVAC module-auxiliary. 2. Install the HVAC module pass thru seal-auxiliary. 3. Install the heater core access cover-auxiliary (3) to the HVAC module-auxiliary. 4. Install the screws to the heater core access cover-auxiliary (3). Tighten the screws to 2 N.m (18 lb in). NOTE: Refer to Fastener Notice in Service Precautions. Page 13035 Cigarette Lighter: Service and Repair CIGAR LIGHTER HOUSING OR 12 VOLT ACCESSORY POWER RECEPTACLE REPLACEMENT TOOLS REQUIRED J 42059 Cigarette Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the 12 volt power supply or cigar lighter fuse. 2. Remove the socket by placing one side of the "T" portion of the tool J 42059 into the socket and into the square window tab. 3. Position the opposite "T" portion of the tool into the opposing square window tab. 4. Pull the socket straight out of the retaining ring. 5. Remove the tool from the socket. 6. Disconnect the electrical connector from the socket. Page 13027 Registered And Non-Registered Trademarks Part 2 Page 9489 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 12061 WA722J/25 - WA765J/37 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 303 For vehicles repaired under warranty, use the table. Disclaimer Page 5935 Park/Neutral Position Switch (C2) Page 30 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Specifications Oil Pan: Specifications Oil Pan Bolt (Ends) 89 inch lbs. Oil Pan Bolt (Sides) 18 ft. lbs. Oil Pan Nut 18 ft. lbs. Oil Pan Stud 97 inch lbs. Page 6792 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 7056 For vehicles repaired under warranty, use the table. Disclaimer Page 9325 Page 3522 Body Control Module (BCM) C3 Part 1 Page 3912 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Application and ID Relay Box: Application and ID Location View Application Table Part 1 Page 2241 Fuse Block - Underhood C3 Part 3 Procedures Trunk / Liftgate Lock Cylinder: Procedures The content of this article/image reflects the changes identified in TSB Bulletin No.: 06-08-66-001 Date: February 14, 2006 SERVICE MANUAL UPDATE Subject: Revised Liftgate Lock Cylinder Replacement Models: 2004-2006 Buick Rainier Models 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Note: When replacing the liftgate lock cylinder, removal of the rear window wiper motor, if equipped, is required. Lock Cylinder Replacement - Liftgate Removal Procedure 1. Remove the rear wiper motor. 2. Remove the lock rod from the lock cylinder. 3. Remove the C clip from the groove in the lock cylinder. Page 9498 Page 2218 Fuse Block - Rear C2 Part 3 Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 1806 Windshield Wiper/Washer Switch (Turn Signal/Multifunction Switch C3) Page 2657 Drive Belt: Testing and Inspection - Symptoms - Drive Belt Drive Belt Chirping See: Drive Belt Chirping Drive Belt Squeal See: Drive Belt Squeal Drive Belt Whine See: Drive Belt Whine Drive Belt Rumbling See: Drive Belt Rumbling Drive Belt Vibration See: Drive Belt Vibration Drive Belt Falls Off See: Drive Belt Falls Off Drive Belt Excessive Wear See: Drive Belt Excessive Wear Drive Belt Tensioner See: Drive Belt Tensioner/Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Page 9688 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 8984 Locations View Page 12134 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 2147 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. .................................................................... R-134a Page 3929 Abbreviations And Meanings Part 16 Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Page 9911 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 12847 Abbreviations And Meanings Part 24 Locations Electronic Components Page 8383 Abbreviations And Meanings Part 3 Page 10817 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 5399 The purpose of this bulletin is to identify the correct oil pump rotor (212) and slide (203) usage for the two different transmission oil pump designs. Manufacturing of the first design oil pump rotor (212) and slide (203) ended November 30, 2000. Manufacturing of the second design oil pump rotor (212) and slide (203) began December 1, 2000. Important: It is critical that the first and second design oil pump rotors and slides do not become intermixed. Do not use first design pump components with second design pump components. If the pump components from either design are intermixed, pump efficiency will be affected resulting in less than optimal pump performance. The first design oil pump rotor (212) and slide (203) DO NOT have any identification markings. Page 5387 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Slde Page 13025 Abbreviations And Meanings Part 26 Page 5220 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Page 9363 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 339 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit EVAP Hoses/Pipes Replacement - Canister/Fuel Tank (Vapor Pipe) Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Canister/Fuel Tank (Vapor Pipe) REMOVAL PROCEDURE CAUTION: Refer to Fuel and EVAP Pipe Caution in Service Precautions. NOTE: Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Service Precautions. 1. Remove the fuel tank. 2. Disconnect the evaporative emission (EVAP) vapor pipe at the fill limiter vent valve (3). 3. Disconnect the EVAP vapor pipe from the front rollover valve (5). 4. Remove the front retaining clip (6) from the fuel and EVAP pipes and remove the EVAP vapor pipe. 5. Disconnect the EVAP vapor pipe from the fill limiter vent valve (3). 6. Disconnect the EVAP vapor pipe from the rear rollover valve (2). 7. Remove the EVAP vapor pipe. INSTALLATION PROCEDURE 1. Connect the fuel tank vapor pipe to the rear rollover valve (2). 2. Connect the fuel tank vapor pipe to the fill limiter vent valve (3). 3. Connect the EVAP vapor pipe to the fill limiter vent valve (3). 4. Install the front clip (6) to the fuel and EVAP pipes at the front of the fuel tank. 5. Connect the EVAP vapor pipe to the front rollover valve (5). 6. Install the fuel tank. Page 13224 Page 13900 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 11209 For 2007 vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 03-08-64-006C Date: 070329 Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Page 2563 10. Place trim tool assembly EN 45680-411 onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block. 11. Install the 4 bolts EN 45680-414 (2) into the cylinder head bolt holes in the block. Tighten Tighten the bolts to 20 Nm (15 lb ft). 12. Fasten drive adapter EN 45680-866 (1) into the drill chuck. 13. Connect a compressed air supply 517-862 kPa (75-125 psi) to the male quick connect (3) located on trim tool assembly EN 45680-411. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings. 14. Place drive adapter EN 45680-866 and drill assembly (1) vertically onto the drive adapter end of trim tool assembly EN 45680-411. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds. 15. Remove drive adapter EN 45680-866 (1) and drill assembly from the trim tool assembly EN 45680-411. 16. Turn off the compressed air valve (2). 17. Remove trim tool assembly EN 45680-411 from the engine block. 18. Remove any material shavings that may be found on the metal shaving catch plug EN 45680-413. 19. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the metal shaving catch plug EN 45680-413. Manual Transmission - M/T Operating Characteristics Manual Transmission/Transaxle: Technical Service Bulletins Manual Transmission - M/T Operating Characteristics INFORMATION Bulletin No.: 03-07-29-004G Date: December 15, 2010 Subject: Manual Transmission Operating Characteristics Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2009 and Prior Chevrolet and GMC Medium Duty Trucks 2006-2010 HUMMER H3 with Manual Transmission Supercede: This bulletin is being revised to add the 2011 model year and to add Cold Operation information. Please discard Corporate Bulletin Number 03-07-29-004F (Section 07 Transmission/Transaxle). Important Even though this bulletin attempts to cover operating characteristics of manual transmissions, it cannot be all inclusive. Be sure to compare any questionable concerns to a similar vehicle and if possible, with similar mileage. Even though many of the conditions are described as characteristics and may not be durability issues, GM may attempt to improve specific issues for customer satisfaction. The purpose of this bulletin is to assist in identifying characteristics of manual transmissions that repair attempts will not change. The following are explanations and examples of conditions that will generally occur in all manual transmissions. All noises will vary between transmissions due to build variation, type of transmission (usually the more heavy duty, the more noise), type of flywheel and clutch, level of insulation, etc. Basic Information Many transmission noises are created by the firing pulses of the engine. Each firing pulse creates a sudden change in angular acceleration at the crankshaft. These changes in speed can be reduced with clutch damper springs and dual mass flywheels. However, some speed variation will make it through to the transmission. This can create noise as the various gears will accel and decel against each other because of required clearances. Cold Operation Manual transmission operation will be affected by temperature because the transmission fluid will be thicker when cold. The thicker fluid will increase the amount of force needed to shift the transmission when cold. The likelihood of gear clash will also increase due to the greater time needed for the synchronizer assembly to perform its function. Therefore when the transmission is cold, or before it has reached operating temperature, quick, hard shifts should be avoided to prevent damage to the transmission. Gear Rattle Rattling or grinding (not to be confused with a missed shift type of grinding, also described as a combustion knock type of noise) type noises usually occur while operating the engine at low RPMs (lugging the engine). This can occur while accelerating from a stop (for example, a Corvette) or while operating at low RPMs while under a load (for example, Kodiak in a lower gear and at low engine speed). Vehicles equipped with a dual-mass flywheel (for example, a 3500 HD Sierra with the 6-speed manual and Duramax(R)) will have reduced noise levels as compared to vehicles without (for example, a 4500 Kodiak with the 6-speed manual and Duramax(R)). However, dual-mass flywheels do not eliminate all noise. Neutral Rattle There are often concerns of rattle while idling in neutral with the clutch engaged. This is related to the changes in angular acceleration described earlier. This is a light rattle, and once again, vehicles with dual mass flywheels will have reduced noise. If the engine is shut off while idling in neutral with the clutch engaged, the sudden stop of the engine will create a rapid change in angular acceleration that even dual mass flywheels cannot compensate. Because of the mass of all the components, this will create a noise. This type of noise should not be heard if the clutch is released (pedal pushed to the floor). Backlash Backlash noise is created when changing engine or driveline loading. This can occur when accelerating from a stop, coming to a stop, or applying and releasing the throttle (loading and unloading the driveline). This will vary based on vehicle type, build variations, driver input, vehicle loading, etc. and is created from the necessary clearance between all of the mating gears in the transmission, axle(s) and transfer case (if equipped). Specifications Brake Bleeding: Specifications Brake System Pressure Bleed Initial Pressure Adjustment Setting, Leak 10 psi Testing the Hydraulic Brake System. Pressure Bleed Procedure Setting 35 psi Page 11838 Abbreviations And Meanings Part 23 Procedures Power Seat Switch: Procedures Lumbar Switch Replacement - Front LUMBAR SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the switch bezel assembly from the seat. 2. Remove the power seat switch. 3. Release the tabs that retain the lumbar switch to the switch bezel assembly. 4. Disconnect the electrical connector from the lumbar switch. 5. Remove the lumbar switch from the switch bezel assembly. INSTALLATION PROCEDURE 1. Connect the electrical connector to the lumbar switch. 2. Install the lumbar switch to the switch bezel assembly, verifying that the retaining tabs are fully seated. 3. Install the power seat switch. 4. Install the switch bezel assembly to the seat. Seat Switch Bezel Replacement SEAT SWITCH BEZEL REPLACEMENT REMOVAL PROCEDURE Page 12163 Abbreviations And Meanings Part 8 Page 3893 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 10306 Page 10277 Speaker - RF Door Page 48 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 2949 Abbreviations And Meanings Part 21 Page 1794 Windshield Washer Fluid Level Switch Page 13431 Canadian dealers should refer to the Canadian distribution of the bulletin for detailed claim information. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Page 8598 8. Remove the evaporator core (3) from the HVAC module-auxiliary (1). 9. Carefully remove the foam insulator (2) from around the evaporator core-auxiliary (3). INSTALLATION PROCEDURE 1. Transfer the foam insulator (2) to the replacement evaporator core-auxiliary (3). 2. Transfer the thermal expansion valve-auxiliary to the replacement evaporator core-auxiliary.Install the evaporator core-auxiliary (3) to the rear HVAC module-auxiliary (1). 3. Install the HVAC module-auxiliary case sump (2). 4. Install the screws to the HVAC module-auxiliary case sump. Fuel System - Fuel Spit-Back/Early Pump Nozzle Shut-Off Fuel Filler Neck: All Technical Service Bulletins Fuel System - Fuel Spit-Back/Early Pump Nozzle Shut-Off Bulletin No.: 04-06-04-003A Date: August 11, 2004 TECHNICAL Subject: Vehicle is Difficult to Fill with Fuel or Filling Station Pump Shuts Off Before Tank is Full or Fuel Spits Back/Out When Filling Tank (Replace Fuel Tank Filler Upper Pipe and Lower Hose) Models: 2003 Chevrolet TrailBlazer with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2003 GMC Envoy with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2003 Oldsmobile Bravada with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL 2004 Buick Rainier 2004 Chevrolet TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Envoy XUV 2004 Oldsmobile Bravada Built Prior to December 2003 Supercede: This bulletin is being revised to provide new part number for 2002-2003 vehicles. Please discard Corporate Bulletin Number 04-06-04-003 (Section 06 - Engine/Propulsion System). This bulletin provides information on two different conditions. Condition 1 Some customers may comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. Cause This condition may be caused by the variability (fuel flow rates, type of fuel fill nozzle, fuel properties) at the filling stations. There is a potential to develop an increase in back pressures internal to the fuel fill neck. This back pressure trips the fuel nozzle prior to filling the tank, or results in a hard to fill condition. Condition 2 Some customers may comment that when filling the fuel tank, a small amount of fuel may spit back/out. Cause This condition may be caused by the equalization of pressure between the fuel tank and the fuel fill neck that does not react quickly to the variance in the pressure when the fueling station fuel nozzle trips off. Correction Replace the fuel tank filler upper pipe assembly with P/N 88983256 or P/N 15131043, and lower hose assembly with P/N 15131046. The new upper pipe has been redesigned to provide smoother flow conditions within the section and the lower hose has been redesigned to include a checking feature. Use the procedure listed below. 1. Remove the fuel fill cap. 2. Remove the fuel fill pipe housing. Page 12228 Memory Seat Module - Driver C3 Part 3 Page 6227 Abbreviations And Meanings Part 26 Page 3588 Powertrain Control Module (PCM) C3 Part 3 Page 12782 Page 9908 Page 2812 Abbreviations And Meanings Part 10 Page 6866 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 10499 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Only if necessary remove the fuel tank shield. IMPORTANT: Due to an access hole in the fuel tank shield, removal of the shield should not be necessary to access the fuel pressure service connection. 3. Remove the fuel pressure service connection cap, located near the fuel filter. 4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Turn ON the ignition. 6. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 8. Command the fuel pump ON with a scan tool. 9. Close the bleed valve on the fuel pressure gage. 10. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. Page 11775 Page 9045 Disclaimer Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the grille. 3. Remove the headlamp wire harness from the retaining clip (1). 4. Raise and support the headlamp wire harness (1) to gain access to the front end sensor. Page 8037 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Page 8263 4. Install the retaining screw (1) to the driver side window defroster duct (4). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screw to .....2 N.m (18 lb in). 5. Install the passenger side window defroster duct. 6. Install the passenger side window defroster duct (3) retaining screw (4). Tighten Tighten the nut to .....2 N.m (18 lb in). 7. Install the I/P assembly. Page 622 Door Module: Connector Views Driver Door Module (DDM) - C1 Page 10618 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 13929 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 13992 Heated Glass Element: Removal and Replacement Rear Window Defogger Braided Lead Wire Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. 1. Use a solder containing 3 percent silver and a rosin flux paste in order to solder and attach the rear defogger bus bar lead wire and/or defogger terminal. 2. Buff the repair area with a fine steel wool in order to remove the oxide coating that was formed during window manufacture. 3. Use a brush in order to apply the paste-type rosin flux in small quantities to the appropriate area: * The rear defogger bus bar lead wire * The defogger terminal repair area Caution: Refer to Window Retention Caution in Service Precautions. Important: Do not hold the tool in one spot or operate the tool on the window for longer than 30-40 seconds. If the window becomes hot to the touch, allow the window to air cool before proceeding further. Cooling with water may crack the heated window. Avoid excessive pressure in order to ensure that the window will not overheat. 4. Coat the solder iron tip with solder. Apply only enough heat to melt the solder and only enough solder to ensure a complete repair. 5. Apply the solder to the feed bus bar or the ground bus bar. Draw the soldering iron tip across the fluxed area. Thinly coat the bus bar with solder. 6. Apply a small amount of flux to the appropriate areas: * The underside of the rear defogger bus bar lead wire * The defogger terminal 7. Align the spots with the flux to the appropriate areas: * The underside of the rear defogger bus bar lead wire * The defogger terminal 8. Coat the tip of the soldering iron with solder. 9. Solder the appropriate areas: * The underside of the rear defogger bus bar lead wire * The defogger terminal 10. Draw the iron across the fluxed spot. Thinly coat the spot with solder. 11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar. 12. Use pliers in order to hold the appropriate component: * The rear defogger bus bar lead wire * The defogger terminal 13. Apply heat to the appropriate area in order to ensure the solder spot melts and fuses together: * The top of the rear defogger bus bar lead wire Page 54 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 6346 9. Install the rear brake caliper assembly. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Caution: Refer to Firm Brake Pedal Caution in Service Precautions. 12. Pump the brake pedal slowly and firmly in order to seat the brake pads. Page 9103 2. Position the sensor assembly horizontally above the front bumper. 3. Connect the sensor (2) electrical connector. 4. Install the connector-position assurance (CPA) to the sensor electrical connector. 5. Install the retaining bolts and protective cover (1) to the sensor. 6. Position the sensor assembly horizontally to the frame (1). 7. Point the arrow on the sensor toward the front of the vehicle. 8. Install the 2 bolts (1) retaining the discriminating sensor assembly to the frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 8 N.m (71 lb in). Page 12933 Abbreviations And Meanings Part 22 Page 12357 Memory Seat Module - Driver C3 Part 3 Page 2466 Wheel Nut Torque Sequence Page 13139 Abbreviations And Meanings Part 11 Page 241 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 8987 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 3 Page 866 Abbreviations And Meanings Part 11 Page 9353 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 6689 Abbreviations And Meanings Part 11 Page 1731 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 12147 Conversion - English/Metric Part 2 Page 9039 Disclaimer OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 7465 C108 Part 2 Locations Park Neutral Position (PNP) Switch Page 1775 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR REMOVAL PROCEDURE 1. Using a flat-bladed tool, remove the window switch bezel from the door trim panel. 2. Disconnect the electrical connector from the window switch. 3. Release the retaining clips that attach the power window switch to the bezel. 4. Remove the switch from the bezel. INSTALLATION PROCEDURE 1. Install the switch to the bezel. Ensure that the retainers are fully seated. 2. Connect the electrical connector to the window switch. 3. Install the window switch bezel to the door trim panel. 4. Ensure that the window switch bezel retaining clips are fully seated. Page 10059 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 10373 Abbreviations And Meanings Part 26 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Service and Repair Front Door Latch: Service and Repair Latch Replacement - Front Door Removal Procedure 1. Close the window to the full up position. 2. Remove the door trim panel. 3. Remove the rear half of the water deflector. 4. Disconnect the lock rod retaining clip from the outside door handle. 5. Remove the lock rod from the outside door handle. 6. Disconnect the lock cylinder rod from the cylinder, if equipped. 7. Remove the inside door handle. 8. Remove the 3 screws that retain the latch to the door. 9. Position the latch in order to disconnect the electrical connectors as needed. 10. Remove the latch from the door. 11. Noting the position of the inside handle lock rods, remove the inside handle lock rods from the latch. 12. Noting the position of the outside handle lock rods, remove the outside handle lock rods from the latch. 13. Remove the actuator from latch. Installation Procedure 1. Install the actuator to the latch. Page 12360 Memory Seat Module - Driver C4 Part 3 Page 2749 4. Inspect the oil pan alignment. Use a straight edge on the back of the block and the oil pan transmission mounting surface. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 5. Install the oil pan bolts. - Tighten the oil pan side bolts to 25 Nm (18 ft. lbs.). - Tighten the oil pan end bolts to 10 Nm (89 inch lbs.). 6. Install the 4 transmission bell housing bolts that attach to the oil pan. Tighten bolts to 47 Nm (35 ft. lbs.). 7. Install the A/C compressor 2 bottom bolts (4). Tighten all 4 bolts to 50 Nm (37 ft. lbs.). 8. Install the front differential bolts. Tighten the front differential bolts to 85 Nm (63 ft. lbs.). 9. Install the front drive axle, clutch fork assembly. Page 4609 Fuel Injector 4 Page 600 Abbreviations And Meanings Part 12 Page 9182 Abbreviations And Meanings Part 15 Page 11046 Important: Punch the center of the weld so that as much of the weld as possible is removed during drilling. 5. Center punch each weld location (1). Important: Drill through the hinge base only (1). Do not drill through the mating surface (2). 6. Remove the hinge tab (3) before drilling, if necessary. 7. At each punch location, drill a 3 mm (1/8 in) pilot hole (1). 8. Using the pilot hole as a guide, drill through the hinge base using a 19 mm (3/4 in) rotabroach hole saw or equivalent (2). Important: If necessary, use a chisel to separate the hinge from the mating surface. 9. Remove the hinge. Intermediate Steering Shaft Replacement - Upper Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement - Upper Intermediate Steering Shaft Replacement - Upper Tools Required ^ J42640 Steering Column Lock Pin Removal Procedure Notice: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 1. Turn the steering wheel so that the front wheels are pointing straight ahead. 2. Turn the ignition switch to the lock position and remove the key. 3. Lock the steering column through the access hole in the lower steering column trim cover using J42640. 4. Remove the knee bolster. 5. Disconnect the upper intermediate shaft boot from the lower intermediate shaft boot to gain access to the upper intermediate shaft to lower intermediate pinch bolt. 6. Remove the upper intermediate shaft to lower intermediate shaft pinch bolt. 7. Disconnect the upper intermediate shaft from the lower intermediate shaft. Important: Note the direction of upper intermediate shaft to steering column pinch bolt for installation. The bolt must be installed in the same direction it was removed. Page 10860 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 12830 Abbreviations And Meanings Part 7 A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 10349 Abbreviations And Meanings Part 2 Page 7299 Auxiliary Power Outlet - Front A/C - Stops Blowing Cold Air/Cycles ON and OFF Refrigerant: Customer Interest A/C - Stops Blowing Cold Air/Cycles ON and OFF File In Section: 01 - HVAC Bulletin No.: 02-01-39-006A Date: May, 2003 INFORMATION Subject: Diagnosing Poor A/C Performance - A/C Stops Blowing Cold, A/C Cycles On and Off Models: 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL with Automatic or Manual HVAC Auxiliary Temperature Control (RPOs CJ2 or CJ3) This bulletin is being revised to include the underhood label part number. Please discard Corporate Bulletin Number 02-01-39-006 (Section 01 - HVAC). Some of the above listed vehicles may exhibit poor A/C performance due to an overcharged system. If the A/C system is overcharged, it may cause the A/C to stop blowing cold after extended idle or while driving in slow traffic at high ambient temperatures. It has been found that the underhood label containing the A/C charge specification is incorrect. The correct specification should read System Charge with Front and Rear -1.20 kg (2.65 lbs) Use this new charge specification whenever the A/C system is serviced. Install new label, P/N 15103173. Parts Information Parts are currently available from GMSPO. Disclaimer Page 9790 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 11694 8. Pull the sunshade downward while maintaining outboard pressure to the sunshade. You will notice a separation between the headliner and the sunshade bezel. 9. In order to remove the sunshade from the headliner, carefully grab the headliner at the windshield pillar area and apply downward pressure while gently rocking the sunshade up and down. 10. Remove the inboard retainer screw. 11. Remove the inboard retainer (1) from the headliner. 12. If the vehicle is equipped with lighted sunshades, perform the following steps: 1. Reach above the headliner to access the electrical connector (1). 2. Remove the electrical connectors from the headliner substrate. 3. Disconnect the sunshade electrical connector from the headliner harness. 13. Remove the sunshade from the vehicle. Installation Procedure 1. If the vehicle is equipped with lighted sunshades, perform steps 2 through 8: Page 12018 WA534F/54 - WA5456/43 Diagrams Oil Level Sensor For ECM: Diagrams Engine Oil Level and Temperature Sensor Page 2076 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 6966 Fuse Block - Underhood C1 Part 2 Page 13249 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 8386 Abbreviations And Meanings Part 6 Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Only if necessary remove the fuel tank shield. IMPORTANT: Due to an access hole in the fuel tank shield, removal of the shield should not be necessary to access the fuel pressure service connection. 3. Remove the fuel pressure service connection cap, located near the fuel filter. 4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Turn ON the ignition. 6. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 8. Command the fuel pump ON with a scan tool. 9. Close the bleed valve on the fuel pressure gage. 10. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. Page 7247 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 905 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). 7. Disconnect the 40-way body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. Locations Page 23 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 702 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 6448 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10257 Amplifier: Service and Repair Amplifier Replacement 2 AMPLIFIER REPLACEMENT (ENVOY XL, TRAILBLAZER EXT) REMOVAL PROCEDURE 1. Remove the Left rear quarter trim panel. 2. Disconnect the electrical connectors from the radio speaker amplifier. 3. Remove the 4 bolts that retain the radio speaker amplifier to the body. 4. Remove the radio speaker amplifier from the body. INSTALLATION PROCEDURE 1. Install the radio speaker amplifier to the body. 2. Install the 4 bolts that retain the radio speaker amplifier to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (88 lb in). 3. Connect the electrical connectors to the radio speaker amplifier. 4. Install the left rear quarter trim panel. Page 4043 Powertrain Control Module (PCM) C2 Part 5 Page 7236 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 9813 Abbreviations And Meanings Part 5 Page 7355 Fuse Block - Underhood C2 Part 6 Fuse Block - Underhood C3 Part 1 Page 6654 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 5330 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Page 2883 Page 11207 Rear Door Striker: By Symptom Technical Service Bulletin # 03-08-64-006C Date: 070329 Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Page 6469 Important: When performing the following service procedure, apply equal pressure to ensure proper seating of the reservoir and the pin holes are aligned. 3. Install the reservoir to the brake master cylinder. 4. Install the reservoir retaining pins. 5. Remove the brake master cylinder from the vise. 6. Install the brake master cylinder. Page 12709 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 9403 For the list of Driver Warnings, refer to Indicator/Warning Message Description and Operation. Page 11870 Disclaimer Page 13067 Lifgate Ajar Switch Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 10948 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6766 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 10532 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 202 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 12882 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Service and Repair Pinion Bearing: Service and Repair Drive Pinion Bearings Replacement Tools Required ^ J7817 Outer Bearing Race Installer ^ J8092 Universal Driver Handle- 3/4 inch - 10 ^ J8608 Rear Pinion Bearing Race Installer ^ J8611-01 Rear Pinion Bearing Race Installer ^ J8614-01 Flange and Pulley Holding Tool ^ J22912-01 Split-Plate Bearing Puller ^ J24433 Pinion Cone and Side Bearing Installer ^ J33782 Pinion Oil Seal Installer ^ J38694 Extension Housing Oil Pump/Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential. 3. Remove the drive pinion from the axle. 4. Press the bearing off of the pinion using the J22912-01. 5. Remove the shim. 6. Remove the outer pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. Page 2331 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Page 658 Memory Seat Module - Driver C2 Part 1 Page 8346 A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: Customer Interest A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Page 580 Conversion - English/Metric Part 2 Page 3918 Abbreviations And Meanings Part 5 Page 13556 Page 6345 4. Apply high temperature silicone brake lubricant to the brake caliper guide pins. DO NOT apply the lubricant to the brake pad retaining clips. 5. Install the brake caliper mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the caliper mounting bracket bolts. ^ Tighten the caliper mounting bracket bolts to 70 Nm (52 ft. lbs.). 7. Install the rear brake pad hardware to the brake caliper mounting bracket. 8. Install the brake pads to the brake caliper mounting bracket. Page 6259 2. Install the piston seal. Make sure the piston seal is not twisted in the caliper bore groove. 3. Install the boot into the caliper housing bore by hand. 4. Install the piston in the caliper bore. Push the piston to the bottom of the bore by hand. 5. Install the boot on the piston. Service and Repair Radiator Cooling Fan Motor Relay: Service and Repair Cooling Fan Relay Replacement Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the underhood electrical center cover. 2. Using the J 43244, remove the cooling fan relay (3). Installation Procedure NOTICE: Installation of the proper relay is critical. If an enhanced relay equipped with a diode is installed into a position requiring a standard relay equipped without a diode; excessive current will damage any components associated with the relay or its associated circuits. 1. Install the cooling fan relay (3). 2. Install the underhood electrical center cover. Page 4741 3. Remove the fuel fill pipe bracket nut (2). 4. Raise and suitably support the vehicle. 5. Remove the fuel fill pipe ground strap bolt. 6. Cut off the ground strap ring terminal and tie strap. 7. Loosen the fuel hose clamp (8). 8. Remove the fuel fill upper pipe (7) from the vehicle. 9. Install the new fuel fill upper pipe into the vehicle. Use P/N 88983256 for 2002-2003 model year vehicles or P/N 15131043 for 2004 model year vehicles. 10. Tighten the fuel hose clamp. Tighten Tighten the clamp to 2.5 N.m (22 lb in). 11. Wrap the excess length of ground strap around the fuel hose as necessary. 12. Install the fuel fill pipe ground strap bolt in its original location. 13. Loosen the fuel hose clamps (1, 3). 14. Remove the lower fuel hose (2) from the vehicle. 15. Install the new lower fuel hose into the vehicle. 16. Tighten the lower fuel hose clamps. Tighten Page 10293 Tape Player: Service and Repair CASSETTE PLAYER CARE AND CLEANING TOOLS REQUIRED J 39916-A CD and Cassette Diagnostic Kit Follow the recommended cleaning schedule: 1. Clean the cassette player every 15 hours for the best performance. 2. Clean the cassette player every 50 hours in order to prevent damage to the tape head. Clean the following 2 parts on the tape player: - The head - The capstan Leave the tape player in the vehicle, since you can reach the parts through the tape door. Perform this service at least every 50 hours of cassette operation. After 50 hours of tape play, CLN (Clean) appears on the display as a reminder. Although the system will still function when this message is displayed, the following conditions may occur until the head and the capstan are cleaned: - Reduced sound quality - Damage to the cassette tapes After cleaning the cassette tape player, press and hold EJECT for 5 seconds in order to reset the CLN indicator. The radio displays - - - in order to show that the clean feature has been reset. Failure to clean the cassette player regularly may cause the following conditions: - Reduced sound quality - Damage to the cassettes - Damage to the mechanism Keep the cassette tapes correctly stored in their plastic cases away from the following conditions: - Contaminants - Direct sunlight - Extreme heat Failure to correctly store the cassette tapes may cause the following conditions: - Improper operation of the cassette tapes - Premature failure of the tape player The cassettes are subject to wear. The sound quality may degrade over time. Before servicing a tape player, verify that the following conditions exist: - The cassette tape is in good condition. - The tape player is clean. Clean the tape player at least after every 50 hours of use in order to provide optimum performance. The radio displays CLN as a reminder every 50 hours. If a reduction in the sound quality occurs, regardless of when the tape player was last cleaned, play a different cassette tape in order to see if the tape or the tape player is at fault. If the second cassette tape results in no improvement in sound quality, clean the tape player. Page 4698 16.4. Inspect for fuel leaks. 17. Install the fuel tank shield, if equipped. Page 1540 Inflatable Restraint Electronic Frontal Sensor Page 6840 Seat Belt Replacement - Front Seat Belt: Service and Repair Seat Belt Replacement - Front REMOVAL PROCEDURE 1. Remove the seat switch bezel. 2. Remove the seat trim panel. 3. Remove the seat belt anchor nut from the seat adjuster assembly. 4. Remove the screw from the front seat back seat belt bezel. 5. Slide the bezel off the seat belt. 6. Remove the seat back cover and pad. 7. Remove the seat back panel from the seat back frame. 8. Remove the seat belt from the retractor bracket by sliding the seat belt through the slot. Page 13780 Combination Switch: Diagrams Turn Signal /Mutifuction Switch C1 Page 8998 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the LF door trim panel. 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. Page 12803 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 6801 Abbreviations And Meanings Part 5 Page 12909 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 5414 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON(R) transmission fluid. Page 2895 Oil Pressure Gauge: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 1521 33. Install the new hose, # 1003 (L6 engine) or # 1004 (V8 engine) onto the auxiliary heater pump inlet port. Connect the other quick connect end to the engine. Page 9819 Abbreviations And Meanings Part 11 Page 13941 Abbreviations And Meanings Part 11 Page 10134 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Page 7186 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 9370 Abbreviations And Meanings Part 4 Page 4429 Manifold Absolute Pressure (MAP) Sensor Page 11787 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 12070 WA8554/40 - WA8555/41 Page 9903 Page 3617 operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. 2. Install the ECT sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. Ignition System - MIL ON/Misfire DTC's In Wet Weather Cowl Moulding / Trim: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 12995 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 82 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 4380 Camshaft Position (CMP) Sensor Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Read this procedure carefully and completely. 2. The BCM will not function properly if the Setup New BCM procedure is not performed. 3. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Page 5936 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 12424 3. Install the seat back panel to the frame with push pins (1). 4. Install the seat back cover and pad to the seat back. 5. Install the inboard/outboard rear seat back cushion hinge covers with the three screws. Tighten Tighten the seat back cushion hinge cover screws to 2 N.m (18 lb in). Page 8803 Air Temperature Sensor-Upper Right Page 2240 Fuse Block - Underhood C3 Part 2 Page 11790 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 4947 2. Install the spark plugs to the engine. Tighten the spark plugs to 18 Nm (13 lb ft). 3. Install the ignition coils. Refer to Ignition Coil Replacement. Page 9561 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 6155 Page 412 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 813 Electrical - SES Lamp ON/DTC's P0480/P0526/P1481/P1484 Radiator Cooling Fan Motor: Customer Interest Electrical - SES Lamp ON/DTC's P0480/P0526/P1481/P1484 Bulletin No.: 05-06-02-012B Date: October 19, 2006 TECHNICAL Subject: Service Engine Soon (SES) or Check Engine Light On, DTC P0480/P0526/P1481/P1484 Set (Replace Engine Cooling Fan Wiring Harness) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2005-2006 GMC Envoy Denali, Envoy XL Denali 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add DTC P1484. Please discard Corporate Bulletin Number 05-06-02-012A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the Service Engine Soon (SES) or Check Engine light is illuminated. This condition may be intermittent and upon investigation, the technician may find either DTC P0480, P0526, P1481 or P1484 set. Cause This condition may be caused by the cooling fan harness chaffing against the plastic guide it routes through. This contact may damage the insulation of the wires enclosed in that harness. Correction Replace the engine cooling fan harness using the procedure listed below. Remove the cooling fan. Refer to the Cooling Fan and Shroud Replacement procedure in the Engine Cooling sub-section of SI. Place the cooling fan assembly on a bench. Disconnect the harness electrical connector from the cooling fan clutch. Remove the harness from the plastic guide while feeding the wires out of the slot. Before installing the new harness, wrap the affected area on the wires with electrical tape to keep the protective sleeve in place. Be sure to keep the tape Page 9243 Disclaimer Page 5076 For vehicles repaired under warranty, use the table. Disclaimer Diagrams Camshaft Actuator Solenoid Assembly Page 8357 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 4140 Abbreviations And Meanings Part 26 Page 9049 Seat Belt Buckle: Service and Repair Buckle Replacement - Center Rear REMOVAL PROCEDURE 1. Adjust the left rear seat back to a cargo position. 2. Adjust the seat filler panel on the bottom of the seat back in order to access the center rear seat back mounting nut. 3. Remove the rear seat back mounting nut. 4. Return the seat to an upright position. 5. Remove the clip(s) that retain the seat belt buckle anchor plate to the latch bracket. 6. Remove the seat belt buckle/anchor plate from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt buckle/anchor plate to the vehicle. 2. Install the clip(s) that retain the seat belt buckle/anchor plate to the latch bracket. 3. Adjust the left seat back to a cargo position. 4. Adjust the seat filler panel in order to access the center rear seat back bracket/seat belt buckle anchor plate. 5. Install the center seat back/seat belt buckle mounting nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the center rear seat back mounting nut to 45 N.m (33 lb ft). 6. Return the seat to an upright position. Page 11614 2. Starting with position 1, insert the tumblers (4) into their corresponding slots in the coded order. 3. Using your fingers, pull out the side bar (3) until the tumblers fall completely into place. 4. Insert one tumbler spring (2) above each tumbler (4). 5. Lubricate the tumblers using Superlube(r) GM P/N 12346241 or equivalent. 6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder. 7. Press down the retainer (1) until fully seated in the depression. Page 2025 3. Remove the heater outlet hose (3) from the heater core (1). 4. Position the outlet heater hose clamp (6) at the water pump using J 38185. 5. Remove the heater outlet hose (7) from the outlet hose fitting. 6. Remove the heater outlet hose. INSTALLATION PROCEDURE Page 13015 Abbreviations And Meanings Part 16 Page 8777 For vehicles repaired under warranty, use the table. Disclaimer Page 10301 Page 13669 Involved are certain 2004 Buick Rainier, 2003-2004 Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts Pre-ship Information - For US Only Important: An initial supply of flashers required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of July 18, 2005, and will be approximately 10% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Page 3134 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Turn OFF the ignition switch. 2. Remove the ignition coils. Refer to Ignition Coil Replacement. Notice: Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. Notice: Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure Notice: Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. Notice: Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gauge to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. Refer to Ignition System Specifications, See: Specifications Correct as necessary. Notice: Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Page 10217 Parts Information Page 7993 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Page 3107 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5192 4. Install the J25025-B (2, 3) to the transmission case. 5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the gaskets to the spacer plate. ^ The case gasket is identified by a C. Be sure to place the case gasket on the transmission case side of the spacer plate. ^ The valve body gasket is identified by a V. Be sure to place the valve body gasket on the valve body side of the spacer plate. 6. Ensure that the solenoid screens (1, 2) are in place on the spacer plate. 7. Place the checkball (3) on the spacer plate in the location shown. 8. Place the 3-4 accumulator spring (4) on the spacer plate. 9. Install the spacer plate and related components to the transmission. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the spacer plate support and the spacer plate support retaining bolts. ^ Tighten the spacer plate support retaining bolts to 11 Nm (97 inch lbs.). Page 10207 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 8501 HVAC Control Module - Auxiliary (Body Type VIN 6) Part 1 Page 13798 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11613 Console: Service and Repair Key and Lock Cylinder Coding KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE The lock cylinder keyway is designed so that other model keys will not enter a current model lock cylinder. A single key is used for all locks on the vehicle. The key identification is obtained from the four-character key code stamped on the knockout portion of the key head. Knock the plugs out of the key head after code numbers have been recorded. The code list, available to owners of key cutting equipment from equipment suppliers, determines the lock combinations from the code numbers. CUTTING KEYS After the code has been determined from the code list or the key code diagram, perform the following steps: 1. Cut a blank key to the proper level of each of the tumbler positions. 2. Inspect the key operation in the lock cylinder. REPLACEMENT LOCK CYLINDERS New lock cylinders (except ignition lock cylinders) are available from the service parts warehouse with new lock cylinder locking bars. The tumblers are also available and must be assembled into the cylinder as recommended. For additional information, refer to the following. LOCK CYLINDER TUMBLER OPERATION All lock tumblers are shaped alike with the exception of the notched position on one side. As the key is inserted into the lock cylinder, the tumblers are lowered to the correct height so that notches on each tumbler are at the same level. When the notches on all 6 tumblers line up, 2 small springs push the side bar into the notches, allowing the cylinder to turn in the cylinder bore. Five types of tumblers are used in making the lock combinations, and each is coded and stamped with a number between 1 and 5. ASSEMBLING AND CODING IGNITION LOCK CYLINDERS TOOLS REQUIRED J 41340 Ignition Lock Holding Fixture 1. Determine the tumbler numbers/arrangement: 1.1. Place the tip of the key directly over the tip of the illustrated key. 1.2. Inspect that the diagram outlines the key. 1.3. Starting with position 1 (open end of cylinder), find and record the lowest level (tumbler number) that is visible. 1.4. Repeat the previous step for positions 2-10. Page 8303 16. Remove the nut and bolt securing the coolant recovery reservoir. 17. Remove the coolant recovery reservoir with the accumulator attached. 18. Remove the evaporator tube nut at the evaporator. 19. Remove the evaporator tube from the evaporator 20. Using the J 43181, disconnect the heater hoses from the core. 20.1. Install the J 43181 to the heater core hose. 20.2. Close the tool around the heater core hose. 20.3. Firmly pull the tool into the quick connect end of the heater hose. 20.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 21. Disconnect the coolant bypass valve hose from the auxiliary rear heater line. 22. Disconnect the coolant bypass valve hose from the engine. 23. Disconnect the electrical connector from the coolant bypass valve. This connector will no longer be used. Tape off with electrical tape. 24. Disconnect the vacuum hose from the coolant bypass valve. 25. Remove the nut retaining the coolant bypass valve to the cowl and remove the coolant bypass valve with hoses attached. 26. Remove the heater hose quick connect retainers from the heater core pipes. 27. Remove the four nuts and the HVAC plate from the dash panel. 28. Attach the new auxiliary heater pump to the new bracket using the supplied retainers as shown. Note the position of the pump on the bracket. Page 604 Abbreviations And Meanings Part 16 Page 11494 Install a new license plate pocket perimeter gasket onto the backside edge of the pocket housing as shown above, starting at the middle of the seal at the top center of the pocket. This will ensure that the seal will be even. When properly installed, there will be 25-50 mm (1-2 in) on either side of the liftgate release handle (2) that the seal (1) does not reach. DO NOT attempt to install the seal on the liftgate directly below the release handle. Install the license plate pocket assembly onto the liftgate. Refer to the License Plate Pocket Replacement procedure in the Body Rear End (2006 MY and prior) or Exterior Trim sub-section of SI. Modify the tightening sequence for the screws that retain the pocket assembly to the liftgate as follows: Push the entire rear license plate pocket assembly upward in the opening of the liftgate. Inspect the perimeter gasket to see if it is properly retained. Tighten Tighten the rear license plate pocket assembly retaining nuts to 5 N.m (44 lb in) in the following order. Tighten the upper left retaining nut first. Tighten the upper right retaining nut second. Tighten the three lower retaining nuts in any order. Parts Information Page 7070 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 10526 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 3582 Powertrain Control Module (PCM) C2 Part 3 Page 578 Various symbols in order to describe different service operations. Page 841 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 11041 Important: Punch the center of the weld so that as much of the weld as possible is removed during drilling. 5. Center punch each weld location (1). Important: Drill through the hinge base only (1). Do not drill through the mating surface (2). 6. At each punch location, drill a 3 mm (1/8 in) pilot hole (1). 7. Using the pilot hole as a guide, drill through the hinge base using a 19 mm (3/4 in) rotabroach hole saw or equivalent (2). Important: If necessary, use a chisel to separate the hinge from the mating surface. 8. Remove the hinge. Page 9798 Various symbols in order to describe different service operations. Page 9505 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 3264 Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the 4 bolts to the fan blade. Tighten Tighten the bolts to 27 Nm (20 lb ft). 3. Install the fan clutch to the fan shroud. 4. Install the cooling fan and shroud. Refer to: See: Fan Shroud/Service and Repair Page 8820 Blower Motor Switch-Front Auxiliary Page 1574 For vehicles repaired under warranty, use the table. Disclaimer Page 2284 Relay Box: Service and Repair Rear Electrical Center or Junction Block Replacement REAR ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a cargo position. 4. Remove the rear electrical center cover. 5. Remove the battery feed terminal nut (2) from the junction block. 6. Remove the body control module (BCM) from the rear electrical center. 7. Fully loosen the 3 bolts (1) that retain the junction block to the electrical connectors. Page 7293 Registered And Non-Registered Trademarks Part 3 Page 3482 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 1920 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Page 10462 For vehicles repaired under warranty use, the table. Disclaimer Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: All Technical Service Bulletins Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 352 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 1546 Inflatable Restraint Side Impact Sensor-Right (SISM) Page 4148 Information Bus: Connector Views Data Link Connector (DLC) Page 12913 Abbreviations And Meanings Part 2 Page 4069 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 2232 Fuse Block - Underhood C1 Part 5 Page 1629 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Page 6915 Registered And Non-Registered Trademarks Part 4 Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 3393 Thermostat: Service and Repair Thermostat Replacement (4.2L Engine) Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the necessary coolant from the radiator. 2. Remove the generator. 3. Loosen the outlet hose clamp at the thermostat housing (1). Remove the outlet hose from the thermostat housing. 4. Remove the thermostat housing bolts. 5. Remove the thermostat housing from the engine block. 6. Clean all of the surfaces of the thermostat housing. 7. Clean the sealing surface of the engine block. Installation Procedure Page 6761 Page 11523 Cross-Member: Service and Repair Steering Gear Crossmember Replacement - Rear Steering Gear Crossmember Replacement - Rear Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the front steering gear crossmember rear mounting bolts. 3. Remove the rear steering gear crossmember mounting bolts. 4. Remove the rear steering gear crossmember from the vehicle. Installation Procedure 1. Install the rear steering gear crossmember to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear steering gear crossmember mounting bolts. Tighten the rear steering gear crossmember mounting bolts to 50 N.m (37 lb ft). 3. Install the front steering gear crossmember rear mounting bolts. Tighten the rear steering gear crossmember mounting bolts to 50 N.m (37 lb ft). 4. Lower the vehicle. Page 13221 Page 2807 Abbreviations And Meanings Part 5 Page 11637 6. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 7. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 8. Disconnect the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 9. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 10. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Page 139 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 4977 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 441 Page 6217 Abbreviations And Meanings Part 16 Page 6003 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the grille. 3. Remove the headlamp wire harness from the retaining clip (1). 4. Raise and support the headlamp wire harness (1) to gain access to the front end sensor. Page 2480 The rear end lift points for the floor jack are at the following locations: - Beneath the axle housing, inboard from the shock absorber mounts - Beneath the axle differential Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: - Chock the wheels at the end of the vehicle opposite the end being lifted - Use jack stands for support. Place jack stands at the any of the following locations: - Beneath the frame - Beneath the front suspension crossmember - Beneath the axle When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. NOTE: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: - The catalytic converter - The brake lines - The brake cables - The fuel lines - The accelerator cables - The transmission shift cables Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Page 13949 Abbreviations And Meanings Part 19 Page 6166 Page 10832 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 12908 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Locations Door Switch: Locations Door Jamb Switch, Miniwedge - LR Page 9200 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 12504 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 8941 Electronic Frontal Sensor - Right Locations Memory/Heated Seat Switches Page 3372 operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. 2. Install the ECT sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. Page 558 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 4170 Steps 10-13 OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 2773 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Locations Accelerator Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Press tabs (1) inward and lift to remove the junction block cover. 3. Pull upward on the fuse relay center cover (1) to release the retaining tabs and remove the cover. 4. Note the location and remove the harness end bolts (2) and remove the harness ends from the fuse relay center. 5. Remove the fuse relay center bolts (3) and remove the fuse relay center from the junction block bracket. 6. Pull downward on the wiring harness ends to remove from the bottom of the fuse relay center. A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Page 45 Various symbols in order to describe different service operations. Page 7122 C600 Part 1 Page 464 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 553 Page 12832 Abbreviations And Meanings Part 9 Page 3671 Heated Oxygen Sensor (HO2S) 1 Page 7189 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 11757 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 10314 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 14017 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 3132 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils Page 9667 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 12327 1. Position the head restraint retractor assembly to the seat back. 2. Install the release cable through the head restraint retractor assembly access hole and sliding the cable retainer into position. 3. Install the 3 bolts that retain the head restraint retractor assembly to the seat back frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the head restraint retractor bolts to 10 N.m (88 lb in). 4. Install the seat back cover and pad. Page 10169 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Specifications Valve Cover: Specifications Camshaft Cover Bolts .......................................................................................................................... .................................................... 10 Nm 89 inch lbs. Locations Lock Cylinder Switch: Locations Ignition Switch Locations Electronic Components Page 2764 Page 12490 Page 10885 Abbreviations And Meanings Part 21 Page 2928 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 5743 Valve Body: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 Shift solenoid (4) ^ The 1-2 Shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 Shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the oil pan, gasket, and filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 Shift solenoid (2) ^ The 2-3 Shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 Shift solenoid (6) Page 4225 Cooling System - Electro-Viscous Fan Clutch Operation Fan Clutch: All Technical Service Bulletins Cooling System - Electro-Viscous Fan Clutch Operation Bulletin No.: 06-06-02-003 Date: February 14, 2006 INFORMATION Subject: Operating Characteristics of the Electro-Viscous (EV) Fan Clutch and Diagnostic Tips for Cooling Fan Noise, Delayed Transmission Shifts and/or Engine Revving Too High Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer SS 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X with 4.2L I-6, 5.3L V-8 or 6.0L V-8 Engine (VINs S, P, M, H - RPOs LL8, LM4, LH6, LS2) Date/VIN Breakpoints for Vehicles with New EV Fan Clutch Vehicles built after and including the Date or VIN Breakpoints listed in the table shown are equipped with the new electro-viscous (EV) fan clutch. Vehicles of any model year listed in "Models Affected" with labor code J3390 (claimed after June 8, 2005) with P/N 15293048 in Claim History may also be equipped with this new EV fan clutch. After having service for poor HVAC performance and/or engine cooling performance, some vehicles may exhibit fan noise, delayed transmission shifts, or the engine revving too high. These conditions may be caused by expected operating characteristics of the new design electro-viscous (EV) fan clutch. This new design EV fan clutch has been installed on production vehicles from the end of 2005 model year production (June 2005) and all 2006 model year vehicles. The new design EV fan clutch may also be present on vehicles serviced with this new part per Corporate Bulletin Number 04-01-38-019A or for other service related conditions. The updated design of the electro-viscous (EV) fan clutch helps improve A/C performance but may also produce some additional fan engagement noise. Important: Unless a specific issue is identified by proper SI diagnosis, do NOT replace a fan clutch for fan noise. Specifications Wheel Bearing: Specifications Wheel Hub and Bearing Mounting Bolts 77 ft. lbs. Page 12569 Heated Seat Element And Thermistor Assembly - Front Passenger Back Page 9333 Driver/Vehicle Information Display: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 10872 Abbreviations And Meanings Part 8 Page 13046 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the grille. 6. Remove sensor bracket from bumper. 7. Remove the Connector Position Assurance (CPA) from both (2) electronic frontal sensor (EFS) connectors. IMPORTANT: This vehicle is equipped with two inflatable restraint electronic frontal sensors (EFS). When performing this procedure be sure to include both EFS's. 8. Disconnect both EFS connectors. Zone 2 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 9852 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Programming Universal GARAGE DOOR OPENER PROGRAMMING - UNIVERSAL GARAGE DOOR OPENER PROGRAMMING IMPORTANT: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1, 1982. Be sure that people and objects are clear of the garage door you are programming. The GDO is programmed by using the customer's hand-held transmitter(s). Turn the ignition OFF while programming the GDO transmitter. Follow these steps to program up to 3 channels: 1. If you have previously programmed a transmitter, proceed to Step 2. Otherwise, hold down the 2 outside buttons on the GDO transmitter for approximately 20 seconds, until the light on the GDO transmitter begins to flash rapidly. Then release the buttons. This procedure erases any previous settings and initializes the memory for all 3 channels. 2. Decide which of the 3 channels you want to program to the transmitter you have. 3. Hold the end of the hand-held transmitter against the front surface of the GDO (less than 1 inch) so you can still see the light. 4. Using both hands, press the hand-held transmitter button and the desired button on the GDO transmitter. Continue to hold both buttons through Step 5. 5. Hold down the buttons on both transmitters until you see the light on the GDO transmitter flash slowly and then rapidly. The rapid flashing, which could take up to 90 seconds, indicates that the GDO transmitter has been programmed. Release the buttons on both transmitters when the light starts to flash rapidly. IMPORTANT: The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(TM) at 1-800-355-3515 in order to address this problem. TRAINING THE GDO FOR ROLLING CODE RECEIVERS This procedure is for training the customer's rolling code garage door openers to their GDO transmitter. The GDO must already be programmed to its hand-held transmitter. The training process below must be completed within 30 seconds or it must be repeated. 1. Locate the train button on the garage door opener receiver. Refer to the operator's manual for the garage door opener (or call HomeLink(TM) at 1-800-355-3515 for assistance). Follow instructions for the garage door opener in order to determine when the unit is in train mode. 2. Return to the GDO transmitter in the vehicle, and press the button that you want trained for rolling codes 3 times, for 1 second each time. 3. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(TM) at 1-800-355-3515 in order to address compatibility concerns. ERASING CHANNELS To erase programmed channels, hold down the 2 outside buttons until the light on the GDO transmitter begins to flash. Individual channels cannot be erased, but can be reprogrammed using the Garage Door Opener Programming and the Training GDO for Rolling Code Receivers procedures. Page 9106 Tighten the screws to 8 N.m (71 lb in). 5. Fully seat the water deflector to the door. 6. Install the door trim panel. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 2 and SIR Disabling and Enabling Zone 6. Page 6379 20. Wait approximately 30 seconds, and then inspect the new left front brake pipe and fittings for leaks. Any brake leaks identified must be repaired prior to completing this bleed procedure. 21. Install a proper size box-end wrench onto the left front wheel hydraulic circuit bleeder valve (screw) located on the caliper. 22. Install a transparent hose over the end of the bleeder valve. 23. Submerge the open end of the transparent hose into a transparent container partially filled with DOT-3 brake fluid from a clean, sealed brake fluid container. 24. Loosen the bleeder valve to purge the air from the left front wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, and then tighten the bleeder valve. 25. Close the J 29532, or equivalent, fluid tank valve, and then disconnect the J 29532, or equivalent, form the J 35589-A. 26. Remove the J 35589-A from the brake master cylinder reservoir. 27. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 28. Connect a Tech 2 to the vehicle's diagnostic link connector (DLC) and perform the automatic bleed procedure. 29. After completion of the automatic bleed procedure, slowly depress the brake fluid and verify that it feels firm. Release the pedal. 30. Verify that the fluid in the master cylinder reservoir is at the maximum-fill level. 31. Install the GM Recall Identification Label. Page 11635 6. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 7. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Zone 6 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the RF door trim panel. Page 13184 6. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 7. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 8. Disconnect the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 9. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 10. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 4677 Disclaimer Page 1675 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 2514 7. Remove the camshafts. Important: Once removed, place the valve rocker arms and valve lash adjusters in an organized order so the components can be installed into the original locations. 8. Remove the valve rocker arms. 9. Remove the valve lash adjusters. Installation Procedure Page 7927 3. Connect the air spring level sensor electrical connector. Notice: Failure to remove the air suspension auto level control sensor locating pin before the rear axle support is removed will cause damage to the air suspension auto level control sensor. 4. Remove the air spring level sensor locating pin. 5. Remove the rear axle support. 6. Install the rear tire and wheels. 7. Lower the vehicle. 8. Install the air suspension system fuse. 9. Start the vehicle and run for approximately 1 minute to ensure that the air spring leveling system is functioning properly. 10. Check the D height. Page 9343 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 11779 Page 13311 Miniwedge (Door Jamb Switch) - RR Page 3974 Camshaft Position (CMP) Sensor Page 6023 Torque Converter Clutch Solenoid: Diagrams Torque Converter Clutch Pulse Width Modulated (TGC PWM) Solenoid Valve Connector, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side Page 2655 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Drive Belt Excessive Wear Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Page 1299 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Page 1693 Page 3922 Abbreviations And Meanings Part 9 Page 2681 14. Connect the cooling fan hub nut to the water pump shaft. 15. Install the J41240 to the water pump pulley and tighten the cooling fan hub nut. Tighten the hub nut to 56 Nm (41 ft. lbs.). 16. Connect the battery negative cable. Page 1765 Registered And Non-Registered Trademarks Part 3 Page 6777 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 8337 Page 4188 Manifold Absolute Pressure (MAP) Sensor Page 8354 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 7285 Abbreviations And Meanings Part 21 Page 9947 Disclaimer Page 3105 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 6520 Vacuum Brake Booster: Service and Repair Vacuum Brake Booster Replacement Removal Procedure 1. Apply the parking brake. 2. Remove the master cylinder. 3. Disconnect the vacuum hose from the vacuum booster and from the engine. 4. Remove the left closeout/insulator panel. 5. Remove the pushrod retainer (3) from the brake pedal pin (4). 6. Remove the stop lamp switch (1) and the pushrod (2) from the brake pedal pin (4). 7. Remove the vacuum booster mounting nuts. 8. Remove the vacuum booster assembly. 9. Remove the gasket. Locations Electronic Components Page 12234 Memory Seat Module - Passenger C3 Part 1 Page 7252 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 1697 Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity TrailBlazer 13.9 quarts 13.1 liters TrailBlazer EXT 15.2 quarts 14.4 liters Page 611 Abbreviations And Meanings Part 23 Page 708 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 11014 sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 805 Body Control Module (BCM) Page 13555 1. Remove the 2 screws that retain the insulator panel to the instrument panel (I/P). 2. Release the insulator panel retaining clip from the I/P substrate. 3. Lower the insulator panel. 4. Remove the flasher retaining bracket from the insulator panel. 5. Disconnect the flasher from the electrical connector. 6. Remove the flasher from the vehicle. 7. Position the new flasher to the insulator panel. 8. Connect the electrical connector to the flasher. 9. Install the flasher retaining bracket to the insulator panel. 10. Install the insulator panel tabs to the cowl slots. 11. Raise the insulator panel to the I/P. 12. Install the insulator panel retaining clip to the I/P substrate. 13. Install the 2 screws that retain the insulator panel to the I/P. Tighten Tighten the screws to 2.5 N.m (22 lb in). Page 4234 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 5849 3. Install the axle shaft seal using the J21128. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover and the gasket. 7. Install the tire and wheel assembly. 8. Fill the rear axle with axle lubricant. Use the proper fluid. 9. Lower the vehicle. Page 6231 Registered And Non-Registered Trademarks Part 4 Diagrams Hood Ajar Switch (Export) Page 3838 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 7581 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Locations Door Switch: Locations Door Jamb Switch, Miniwedge - LR Page 6108 Chassis Harness, Frame-Left Side Page 3526 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Page 6173 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 10338 Conversion - English/Metric Part 1 Page 8353 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 13875 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 5963 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9380 Abbreviations And Meanings Part 14 OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 12789 Page 2931 Abbreviations And Meanings Part 3 Page 4282 Abbreviations And Meanings Part 16 Page 11721 1. Remove the cargo shelf. 2. Tumble the third row seats to the cargo position. 3. Remove the right body side window rear garnish molding. 4. Remove the right body side window forward garnish molding. 5. Remove the liftgate sill plate. 6. Remove the right rear door sill panel. 7. Remove the lower seat belt anchor bolt. 8. Release the five screws that retain the rear quarter trim panel to the body. 9. Remove the rear quarter trim panel from the vehicle. INSTALLATION PROCEDURE 1. Position the trim panel to the vehicle. 2. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. Diagrams Transmission Range Switch Connector, Wiring Harness Side Service and Repair Front Door Interior Handle: Service and Repair Door Handle Replacement - Inside Removal Procedure 1. Remove the door trim panel. 2. Remove the handle retaining bolt. 3. Release the handle locator tab from the locator cutout, by sliding the handle forward. 4. Release the rod retainer locks. 5. Remove the rods from the handle. 6. Remove the handle from the door. Installation Procedure 1. Position the handle to the door. 2. Install the rods to the handle. 3. Install the rod retainer locks. 4. Insert the handle locator tab into the locator cutout and move the handle rearward, indexing the fastener hole to the door. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the handle retaining bolt. Tighten bolt to 10 N.m (88 lb in). 6. Install the door trim panel. Page 7611 3. Measure the D height by measuring the distance between the jounce bumper bracket and the top of the rear axle tube. 4. Repeat the jouncing operation and measurement 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true D height dimension is the average of the highest and lowest measurements. Cross vehicle D heights should be within 12 mm (0.5 inch) for vehicles equipped with coil springs, vehicles equipped with air suspension should be within 8 mm (0.3 inch). 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging rear suspension. ^ Collision damage. Page 10490 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 7007 12. Disconnect the body wiring harness connector (1) from the junction block. 13. Disconnect the headliner harness connector (2) from the junction block. 14. Disconnect the console harness connector from the junction block. 15. Remove the block base retaining nuts from the floor studs. 16. Remove the block base from the floor panel. INSTALLATION PROCEDURE 1. Install the block base to the floor studs. 2. Install the block base retaining nuts to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the block base retaining nuts to 10 N.m (88 lb in). 3. Connect the console harness connector to the block base. 4. Connect the headliner harness connector (2) to the block base. 5. Connect the body wiring harness connector (1) to the block base. Electrical Frontal Sensor Impact Sensor: Diagrams Electrical Frontal Sensor Electronic Frontal Sensor - Left Page 9647 Page 2800 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 9978 Page 7691 5. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 6. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Page 13280 Abbreviations And Meanings Part 18 Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 208 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 10867 Abbreviations And Meanings Part 3 Page 4991 Disclaimer Page 828 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 13632 1. Position the headlamp switch near the access hole. 2. Connect the electrical connectors to the headlamp switch. 3. Install the headlamp switch to the IP. Ensure that the retaining tabs are fully seated. 4. Install the left IP access cover. Page 12623 Lumbar Adjuster Switch - Driver (w/ Memory) Page 7170 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 8364 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 9208 Steps 1-6 Page 5461 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4109 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 10672 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 4082 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9579 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 3807 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 12923 Abbreviations And Meanings Part 12 Page 1224 Air Temperature Sensor-Upper Lift Page 9176 Abbreviations And Meanings Part 9 Page 11914 Trunk / Liftgate Lock Cylinder: Removal and Replacement Lock Cylinder Replacement - Lift Gate Removal Procedure 1. Remove the liftgate trim panel. 2. Remove the lock rod from the lock cylinder. 3. Remove the C clip from the groove in the lock cylinder. 4. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the C clip to the groove in the lock cylinder. 3. Install the lock rod to the lock cylinder. 4. Install the trim panel. Page 6284 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Page 6845 Page 4383 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Locations Electronic Components Page 1744 Abbreviations And Meanings Part 8 Page 10045 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 4166 Steps 29-31 The numbers below refer to the step numbers on the diagnostic table. 2. A partial malfunction in the class 2 serial data circuit uses a different procedure from a total malfunction of the class 2 serial data circuit. The following modules communicate on the class 2 serial data circuit: 3. The following DTCs may be retrieved with a history status, but are not the cause of the present condition. - U1300 - U1301 - U1305 6. A state of health DTC with a history status may be present along with a U1000 or U1255 code having a current status. This indicates that the malfunction occurred when the ignition was ON. 7. Data link connector terminals 2 and 5 provide the connection to the class 2 serial data circuit and the signal ground circuit respectively. 10. A poor connection at DLC terminal of the splice pack SP205 would cause this condition but will not set a DTC. 11. This step may eliminate the loop created by PCM and theft deterrent module from failure cause. 12. An open in the class 2 serial data circuit between the DLC and splice pack SP205 will prevent the scan tool from communicating with any module. This condition will not set a DTC. 14. The class 2 serial data circuit is shorted to voltage or ground. The condition may be due to the wiring or due to a malfunction in one of the modules. When testing the wire for a short, make sure there is not a module connected to the wire being tested. This test isolates the BCM class 2 serial data circuits. 16. This test isolates the PCM class 2 serial data circuits. 18. The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must remain connected to the DLC for any other module to communicate with the scan tool. This test isolates the splice pack SP306 serial data circuits. 23. This test isolates the rest of the splice pack SP205 serial data circuits. 27. If there are no current DTCs that begin with a "U", the communication malfunction has been repaired. 28. The communication malfunction may have prevented diagnosis of the customer complaint. Without Immobilizer SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE (W/O IMMOBILIZER) CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the DLC allows communication with the modules for diagnostic purposes. DTCs may be set due to this symptom and during this diagnostic procedure. Complete the diagnostic procedure in order to ensure all the DTCs are diagnosed and cleared from memory. DIAGNOSTIC AIDS - The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must be connected to the DLC for any other module to communicate with the scan tool. - When the class 2 serial data circuit: is shorted to ground - is shorted to voltage The following DTCs may set: U1300 - U1301 - U1305 Page 2551 Important: Once this procedure is done, it is not necessary to reset the trim tool assembly EN 45680-411 height until the blades are worn or damaged. 9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten Tighten the shaft collar screw to 19 N.m (14 lb ft). 10. Place trim tool assembly EN 45680-411 onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block. 11. Install the 4 bolts EN 45680-414 (2) into the cylinder head bolt holes in the block. Tighten Tighten the bolts to 20 N.m (15 lb ft). 12. Fasten drive adapter EN 45680-866 (1) into the drill chuck. 13. Connect a compressed air supply 517-862 kPa (75-125 psi) to the male quick connect (3) located on trim tool assembly EN 45680-411. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings. 14. Place drive adapter EN 45680-866 and drill assembly (1) vertically onto the drive adapter end of trim tool assembly EN 45680-411. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds. 15. Remove drive adapter EN 45680-866 (1) and drill assembly from the trim tool assembly EN 45680-411. 16. Turn off the compressed air valve (2). Page 13945 Abbreviations And Meanings Part 15 Page 5376 15. Disconnect the rear oil cooler lines (2) from the front oil cooler lines (1). 16. Remove the oil cooler lines from the vehicle. Installation Procedure 1. Install the transmission oil cooler lines to the vehicle. 2. Install the transmission cooler lines to the transmission. Notice: Ensure that the cooler line being installed has a plastic cap on each end that connects to a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new plastic cap and position on to the cooler line prior to the cooler line installation. 3. Connect the rear cooler lines (2) to the front cooler lines (1). 4. Raise the transmission into position. 5. Install the front exhaust pipe assembly. 6. Install the transmission support. A/C - Control Knob Replacement Availability Control Assembly: All Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13172 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Page 12749 Rear Door Weatherstrip: Service and Repair Sealing Strip Replacement - Rear Door Upper Sealing Strip Replacement - Rear Door Upper Removal Procedure 1. Starting at the bottom of the sealing strip, pull the sealing strip away from the door pinch-weld flange. 2. Lift upward in order to remove the upper portion of the sealing strip from the door pinch-weld flange. 3. Remove the sealing strip from the door. Installation Procedure 1. Starting at the top of the sealing strip, insert the sealing strip tab into the door sheet metal. 2. Position the sealing strip to the door pinch-weld flange and apply pressure in order to seat the sealing strip. 3. Ensure that the sealing strip is fully seated against the pinch-weld flange. Page 10619 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Interior - Cargo Cover Handle is Broken Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 9672 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 9773 Page 10501 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 13089 Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 12611 Power Seat Motor Position Sensor: Diagrams Position Sensor - Front Motor (w/Memory) Page 7068 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 1508 40.1. Install the ring terminal (black wire) to ground G103 (1), located on the right side inner tender. 40.2. Route the pump wiring harness along the existing right side forward lamp harness. 40.3. Connect the electrical connectors to the coolant bypass valve (1) and auxiliary heater pump (2). 40.4. Position the relays onto the inner wheelhouse panel near the rear of the engine compartment. Page 7352 Fuse Block - Underhood C2 Part 3 Page 10415 Page 10437 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 63 Abbreviations And Meanings Part 8 Page 1746 Abbreviations And Meanings Part 10 Page 11798 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 8709 Do NOT replace an EV fan unless a specific condition related to the EV fan is identified using SI diagnostics. If the fan has a condition that warrants replacement, a DTC should set and/or SI diagnostics should lead to the replacement of the fan clutch. If the fan is not operating at the proper speed/function, the appropriate diagnostic trouble code should set. Identify the root cause of the condition. Please make sure to do a thorough review of SI for proper diagnostics. Several Service Bulletins and Preliminary Information are available on SI regarding the EV fan. Refer to "Operating Characteristics" and "Diagnostic Tips" in this bulletin for additional information. Operating Characteristics of the Electro-Viscous (EV) Fan Clutch Changes to the EV fan clutch to improve the HVAC performance basically increase airflow in certain conditions. It is now possible during start up for the EV fan clutch to be engaged and match engine speed for about 1 minute depending on driving speeds (with lower speeds having a longer disengagement time) producing some noise/flare. The noise/flare will most likely be intermittent and can be dependent on the following conditions: ^ Fan clutch valve orientation, with check ball at 11:00 position as viewed from front of vehicle when the engine is stopped. ^ HVAC or powertrain cooling conditions when the vehicle is shut off. ^ Parking incline - vehicles parked nose up on a 16% or higher incline (such as vehicles coming off transport or parked on steep driveways) may have prolonged fan noise/flare until the fluid is pumped out of the working chamber of the fan. These conditions can occur in as little as ten minutes. Once the vehicle is not parked in these conditions, it should operate as expected. ^ Please note that if the vehicle is parked nose down with a 16% or more decline, the EV fan clutch may have a delayed engagement response similar to what is described in Corporate Bulletin Number 04-01-38-019A. Important: Do not replace EV fan clutches for these conditions listed above; they are expected vehicle characteristics. If the fan clutch is truly operating at a speed higher than intended, a DTC P0495 or P1484 should set. Additional codes are available for other conditions. Diagnostic Tips Depending on the vehicle year, the Tech 2(R) may allow some EV fan control using the special functions application of the Tech 2 (refer to the proper SI documentation). If this function or a fused jumper wire is being used to check EV fan response, there may be a delay in fan response (up to 2-3 minutes depending on conditions, please refer to SI diagnostics). The desired fan speed and actual fan speed data (on the Tech 2(R)) can be misleading. The desired fan speed is comprised of the maximum of multiple parameters (for example engine coolant temp, A/C pressure, etc.) and may not be the ruling desired fan speed parameter. The end result may be that the actual desired fan speed is lower than what is displayed. Additionally, the desired fan speed may be higher than the current engine speed. The fan is limited by the current engine RPM and will max out at about 3500 RPM under full manual fan engagement request along with a corresponding engine RPM speed. The 4.2L 1-6 (LL8) engine's desired and actual fan speeds will usually be closer to each other than the 5.3L V-8 (LM4 or LH6) or the 6.0L V-8 (LS2). Disclaimer Page 11830 Abbreviations And Meanings Part 15 Page 11305 Disclaimer Page 17 Page 5209 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 455 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 6904 Abbreviations And Meanings Part 19 Page 6307 Important: It maybe necessary to readjust the park brake shoes to allow the brake rotor to be reinstalled. 4. Adjust the park brake shoe (1). Important: Ensure that the rotor to axle flange relationships marks are aligned, if the brake rotor has been refinished, after the brake rotor is installed. 5. Install the brake rotor by slowly turning the rotor while pushing the rotor on the axle flange. 6. Install the rear brake caliper mounting bracket. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Refer to Vehicle Lifting. 9. Refill the brake master cylinder reservoir, if needed. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 10. Pump the brake pedal slowly and firmly in order to seat the brake pads. 11. Burnish replaced or refinished rotors. Page 1733 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 7549 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 3477 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 13495 2. Mask off the desired amount of material to be removed. 3. Open the liftgate glass. Note: Do no damage the applique or the liftgate glass when removing the applique from the liftgate glass. 4. Remove the screws that retain the applique to the liftgate glass. 5. With a flat-bladed tool, carefully remove the applique from the liftgate glass. 6. Remove the CHMSL harness grommet from the roof panel. 7. Disconnect the CHMSL harness connector and remove CHMSL applique from the vehicle. 8. Using a 1/4" die grinder and Scotch-Brite(R) Disc, 3M(R) P/N 07481, remove excess material from the applique. 9. Paint the applique to match. Important: If the original part is used, it is important to seal (clear coat) the edge to protect the clear coat from lifting. 10. Remove the old adhesive from the underside of the applique. 11. Clean the application area of the CHMSL applique with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984, or equivalent, and dry thoroughly using a clean low lint towel or towelette. 12. Apply double-sided adhesive tape, 3M(R) P/N 06397, or equivalent, to the underside of the CHMSL applique. 13. Remove the old adhesive from the liftgate glass. Important: ^ The installation area of the liftgate glass must be clean and dry. Any airborne dust, oils, etc., may contaminate the glass or the applique adhesive, and reduce the bond of the tape. ^ DO NOT use commercial glass or surface cleaners. These may contain petroleum. ^ The glass surface temperature should be no lower than 21°C (70°F) and not exceed 38°C (100°F). 14. Clean the application area of the liftgate glass with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984, or equivalent, and dry thoroughly using a clean low lint towel or towelette. 15. Apply adhesive promoter, P/N 12378555, in Canada, use P/N 88901239, to the liftgate glass surface, completely wetting the applique application Service and Repair Refrigerant Temperature Sensor: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the A/C low pressure switch electrical connector. 2. Remove the A/C low pressure switch (2) from the accumulator (1). 3. Remove and discard the O-ring seal from the A/C low pressure switch port on the accumulator. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the A/C low pressure switch (2) to the accumulator (1). Tighten the A/C low pressure switch to 4.8 N.m (42 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the A/C low pressure switch electrical connector. 4. Leak test the fittings of the components using the J 39400-A. Page 8810 3. Install the sensor (1) to the panel assembly (2). 4. Install the front grille. Page 12074 WA8555/41 - WA8624/50 Page 9144 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 10627 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 10288 1. Install the speaker to the IP. 2. Connect the speaker electrical connector. 3. Install the 3 speaker retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the trim pad. Page 10467 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 10682 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 354 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 12170 Abbreviations And Meanings Part 15 Page 4621 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 SYSTEM DESCRIPTION Fuel Injector Balance Test Example (Typical) The scan tool is first used to energize the fuel pump relay. The scan tool is then used to pulse each injector for a precise amount of time allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Steps 1-3 Capacity Specifications Refrigerant Oil: Capacity Specifications Page 9342 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 2905 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 10914 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). 7. Disconnect the 40-way body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. Diagrams Driver Door Lock Cylinder Switch - LF Page 2806 Abbreviations And Meanings Part 4 Page 8978 Knee Diverter: Service and Repair Knee Bolster Replacement KNEE BOLSTER REPLACEMENT REMOVAL PROCEDURE 1. Remove the left closeout/insulator panel. 2. Remove the knee bolster trim panel. 3. Remove the 4 knee bolster retaining nuts. 4. Remove the knee bolster from the steering column support bracket. INSTALLATION PROCEDURE 1. Install the knee bolster to the steering column support bracket. 2. Install the 4 knee bolster retaining nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 10 N.m (88 lb in). 3. Install the knee bolster trim panel. 4. Install the left closeout/insulator panel. Instruments - Erratic Speedometer Operation Speedometer Head: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 6821 Abbreviations And Meanings Part 25 Page 4820 Ignition Coil 4 Page 3473 Various symbols in order to describe different service operations. Page 7558 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear bumper fascia. 2. Using a small flat-bladed tool, apply pressure at two upper locations and two lower locations to release the retainers on the pressure relief valve. 3. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Install the rear bumper fascia. Page 6814 Abbreviations And Meanings Part 18 Page 3892 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 1037 4. Remove the three push-in retainers that attach the air inlet grille (leaf screen) to the plenum sheet metal. 5. Lower the hood to the secondary latch. 6. Using a suitable marker or masking tape, mark the location of both wiper blades on the windshield. 7. Remove the covers from the nuts that attach the wiper arms. 8. Remove the nuts from the wiper arms. Important If the rocking action in the next step fails to loosen the wiper arm, it may be necessary to use a standard top-post battery cable terminal puller to remove the wiper arm. 9. Rock the wiper arms back and forth to loosen and remove them from the wiper transmission shaft. 10. Remove the antenna mast. 11. Remove the 10 mm hex head nut that attaches the left and right ends of the air inlet grille to the plenum sheet metal. 12. Remove the air inlet grille and reposition it up to the windshield. It is not necessary to disconnect the washer hose. 13. Remove the two 10 mm hex head bolts that attach the wiper module to the plenum sheet metal. 14. Disconnect the electrical connector. 15. Remove the wiper module and place on a suitable work surface. Page 2353 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 476 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 4271 Abbreviations And Meanings Part 5 Page 3908 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 11653 8. Inspect for proper tumbler installation: 8.1. Hold the spring retainer (2) in position. 8.2. Insert the key (1) into the cylinder. 8.3. The side bar (3) should drop down flush with the cylinder diameter if properly installed. 8.4. Disassemble and assemble properly as needed. 9. Remove the key. 10. Secure the cylinder in the J 41340. 10.1. Inspect that the spring retainer is facing up and positioned directly under the punch slots. 10.2. Push the cylinder into the J 41340 until butted with the cylinder bezel. 10.3. Tighten the holding screw. 11. Stake the bezel end of the retainer in place: 11.1. Hold the flat side of the punch, part of J 41340, squarely against the face of the cylinder bezel. 11.2. Stake the lock cylinder metal over the retainer corners. Specifications Page 4710 Tighten the clamps to 2.5 N.m (22 lb in). 17. Lower the vehicle. 18. Install the fuel fill pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the fuel fill pipe housing. 20. Install the fuel fill cap. Parts Information Parts are expected to be available from GMSPO on August 13, 2004. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 8507 HVAC Control Module C2 Part 2 Page 11858 Front Passenger Door Module (FPDM) - C2 Part 2 Page 12845 Abbreviations And Meanings Part 22 A/C - Contaminated R134A Refrigerant Refrigerant: All Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Page 1600 Page 12381 1. Install the seat back. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 4 nuts that secure the seat pan to the power seat adjuster frame. Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 3. Install the SIR harness (2) to the seat clips (1,4). 4. Connect the gray lumbar electrical connector (5), if equipped. 5. Connect the black electrical connector (3) to the seat belt buckle. 6. Connect the black electrical connector (6) to the seat back harness. 7. Install the seat belt buckle to the seat with the nut. Tighten the seat belt buckle nut to 55 N.m (41 lb ft). 8. Install the seat cushion trim panel. 9. Install the front bucket seat assembly to the vehicle. Page 11227 1. Install the sealing strip to the pinch-weld flange, starting at the rear edge of the door. 2. Ensure that the sealing strip is fully seated to the pinch-weld flange. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the sealing strip to the door. Tighten the screw to 1.2 N.m (10 lb in). Page 11118 Important: Punch the center of the weld so that as much of the weld as possible is removed during drilling. 5. Center punch each weld location (1). Important: Drill through the hinge base only (1). Do not drill through the mating surface (2). 6. Using the pilot hole as a guide, drill through the hinge base using a 19 mm (3/4 in) rotabroach hole saw or equivalent (2). 7. At each punch location, drill a 3 mm (1/8 in) pilot hole (1). Important: If necessary, use a chisel to separate the hinge from the mating surface. 8. Remove the hinge. Page 1431 Oil Pressure Sensor: Diagrams Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Engine - Balancer Hub Application/Service Precaution Harmonic Balancer - Crankshaft Pulley: Technical Service Bulletins Engine - Balancer Hub Application/Service Precaution Bulletin No.: 04-06-01-003 Date: March 01, 2004 INFORMATION Subject: Information on 2nd Design Balancer Hub Models: 2004 Buick Rainier 2003-2004 Chevrolet Trailblazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Envoy XUV 2003-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Depending on the vehicle and assembly plant, during the late 2003 model year or early 2004 model year, the design of the engine balancer hub was changed. Care should be exercised when servicing any of the vehicles listed above. The 1st design hub is straight and smooth. The 2nd design balancer hub has a step machined on it. The inside diameter of the seal has changed, but the outside diameter has not. It is possible to install either seal into the front cover, however, the incorrect seal will leak between the seal lip and hub of the damper. Note: Be sure to service with the proper combination of balancer, seal and washer. Mixing combinations could lead to an excessive engine oil leak and possible engine failure. Page 10047 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 7310 Application Table Part 1 Page 7366 Application Table Part 1 Fuse Block - Rear (Short Wheelbase) Fuse: Application and ID Fuse Block - Rear (Short Wheelbase) Location View Page 8949 2. Position the sensor assembly horizontally above the front bumper. 3. Connect the sensor (2) electrical connector. 4. Install the connector-position assurance (CPA) to the sensor electrical connector. 5. Install the retaining bolts and protective cover (1) to the sensor. 6. Position the sensor assembly horizontally to the frame (1). 7. Point the arrow on the sensor toward the front of the vehicle. 8. Install the 2 bolts (1) retaining the discriminating sensor assembly to the frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 8 N.m (71 lb in). Page 2686 7. Raise the vehicle and remove the floor jack from under the vehicle. 8. Install the engine protection shield and secure with the bolts. Tighten the engine protection shield bolts to 25 Nm (18 ft. lbs.). 9. Install the right and the left lower engine mount nuts. Tighten the lower engine mount nuts to 70 Nm (52 ft. lbs.). 10. Lower the vehicle. 11. Install the right shock module. 12. Install the MAP sensor (2). 13. Install the MAP sensor retainer (1) and the electrical connector. Specifications Compression Check: Specifications Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. Page 7145 9. Install the 3 bolts (1) that retain the junction block to the block base. Tighten Tighten the 3 bolts to 3.5 N.m (31 lb in). 10. Install the BCM to the rear electrical center. 11. Install the battery feed terminal nut (2) to the junction block. Tighten Tighten the battery feed terminal nut to 10 N.m (88 lb in). 12. Install the rear electrical center cover. 13. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a passenger position. 14. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 15. Connect the battery negative cable. Page 12372 Power Seat Motor: Diagrams Seat Front Vertical Motor - Driver/Passenger Page 11823 Abbreviations And Meanings Part 8 Page 6119 1. Install EBCM (2) onto BPMV (3). Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. 2. Install the four EBCM bolts. ^ Tighten the four bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM (2). 4. Install BPMV (3) to EHCU bracket (5). 5. Connect the two electrical harness connectors to the EBCM (2). Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. 6. Install the 5 brake pipes to the BPMV (3). ^ Tighten the brake pipe fittings to 30 Nm (22 ft. lbs.). 7. Bleed the brake system. Locations Body Control Module: Locations Body Wiring Harness Extension Harness Page 9501 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 559 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 11726 2. Remove the inflator access panel. 3. Remove the right rear quarter upper trim panel. 4. Remove the liftgate sill plate. 5. Remove the right rear door sill panel. 6. Remove the lower seat belt anchor bolt. 7. Release the retaining clips that retain the trim panel to the body. 8. Partially remove the trim panel in order to remove the inflator switch from the inflator bezel. 9. Remove the auxiliary air outlet washer and retaining nut. 10. Feed the auxiliary air outlet through the inflator bezel. 11. Remove the inflator bezel from the trim panel. 12. Disconnect the the 12-volt power supply electrical connector. 13. Remove the 12-volt power supply. 14. Remove the trim panel from the vehicle. Installation Procedure 1. Position the trim panel to the vehicle. 2. Install the 12-volt power supply. 3. Connect the 12-volt power supply electrical connector. 4. Install the inflator bezel to the trim panel. 5. Feed the auxiliary air outlet through the hole in the inflator bezel. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the auxiliary air outlet washer and retaining nut. Tighten the nut to 2 N.m (18 lb in). 7. Install the inflator switch to the inflator bezel. 8. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 9. Align the locating tabs on the trim panel to the holes in the body. 10. Seat the clips that retain the trim panel to the body. 11. Install the seat belt lower anchor. Page 3573 Engine Harness, Fuse Block-Underhood Page 1947 Compression Check: Testing and Inspection Engine Compression Test Tools Required J 38722 Compression Tester A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. Important: The battery must be at or near full charge. 1. Remove the air duct from the throttle control module. 2. Remove the ignition control modules. 3. Disable the fuel system. 4. Remove the spark clues. 5. Measure the engine compression, using the following procedure: 5.1. Firmly install J 38722 to the spark plug hole. 5.2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 5.3. Check and record the readings on J 38722 at each stroke. 5.4. Disconnect J 38722. 5.5. Repeat the compression test for each cylinder. 6. Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. 7. The following are examples of the possible measurements: - When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. - When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. - When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. - When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 8. Install the air duct to the throttle body. 9. Install the spark plugs. 10. Enable the fuel system. 11. Install the ignition control modules. Page 8662 Housing Assembly HVAC: Service and Repair HVAC Module Case - Auxiliary HVAC MODULE CASE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the HVAC module-auxiliary. 2. Remove the screws from the blower motor-auxiliary. 3. Remove the blower motor-auxiliary. 4. Disconnect the electrical connectors. 5. Remove the evaporator core-auxiliary. 6. Remove the screws from the air temperature actuator-auxiliary. 7. Remove the air temperature actuator-auxiliary. 8. Disconnect the electrical connector. 9. Remove the screws from the mode actuator-auxiliary. 10. Remove the mode actuator-auxiliary. 11. Disconnect the electrical connector. 12. Remove all of the screws from the HVAC module-auxiliary. 13. Separate the HVAC module-auxiliary case halves (2,13). 14. Remove the mode door (15) from the HVAC module-auxiliary case half (2). 15. Remove the air temperature door (14) from the HVAC module-auxiliary case half (2). INSTALLATION PROCEDURE 1. Transfer the air temperature door (14) to the HVAC module-auxiliary case half (2). 2. Transfer the mode door (15) to the HVAC module-auxiliary case half (2). 3. Assemble the HVAC module-auxiliary case halves (2,13). Air Suspension Sensor - LR Page 1084 Steering Wheel Controls Page 26 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 541 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 5652 11. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fining. 12. Ensure that the plastic cap is fully seated against the fining. 13. Ensure that no gap is present between the cap and the fitting. 14. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. Recall 05V494000: Rear Door Latch Corrosion Rear Door Latch: By Symptom Recall 05V494000: Rear Door Latch Corrosion MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Trailblazer EXT 2002-2003 GMC/Envoy XL 2002-2003 Isuzu/Ascender 2003 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V494000 MFG'S REPORT DATE: October 26, 2005 COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 98007 SUMMARY: Certain sport utility vehicles have a rear side closure latch that may not latch or unlatch due to corrosion caused by road splash, such as water and road salt. These vehicles are registered or sold in the following states: Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and The District of Columbia. CONSEQUENCE: If the door is not latched properly and it goes unnoticed, it may open while the vehicle is in motion. If an occupant fell out of the vehicle, personal injuries could occur. REMEDY: Dealers will install a seal along the lower part of the rocker panel to prevent intrusion of corrosive material, and inspect the rear side closure latches. Functional latches will be cleaned and lubricated. Non-functioning latches will be replaced. The recall is expected to begin during January 2006. Owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or Isuzu at 1-800-255-6727. NOTES: GM recall No. 05077. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Service and Repair Steering Mounted Controls Transmitter: Service and Repair Steering Wheel Control Switch Assembly Replacement Removal Procedure 1. Remove the steering wheel. 2. Remove the shroud retaining screws from the back of the steering wheel. 3. Remove the shroud from the steering wheel. 4. Position a blunt ended tool into the wire harness cavity (1) and apply moderate pressure in order to partially remove the steering wheel control switch from the steering wheel. 5. Disconnect the steering wheel control switch electrical connector. Important: The bulbs in the steering wheel control switches are not serviceable. The switches should be replaced only as an assembly. OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 3014 13. Install the exhaust camshaft actuator into the timing chain. 14. Align the dark link of the timing chain with the timing mark on the exhaust camshaft actuator (1). Important: It may be necessary to remove the J44221 to rotate and hold the camshaft hex to align the pin to the camshaft sprocket. 15. Install the exhaust camshaft actuator onto the exhaust camshaft. Important: Rotate the camshaft actuator clockwise relative to the camshaft prior to tightening the bolt. 16. Rotate the camshaft actuator clockwise until it stops (as seen from the front of the vehicle). Notice: The camshaft actuator must be fully advanced during installation. Engine damage may occur if the camshaft actuator is not fully advanced. 17. Install the exhaust camshaft actuator bolt. Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 ft. lbs.). Use J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135°. 18. Tighten the intake camshaft sprocket bolt the first pass to 20 Nm (15 ft. lbs.). Use J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100°. 19. Remove the tee in the timing chain tensioner to regain tension on the timing chain. Page 13616 1. Position the bulb and socket to the headlamp. 2. Connect the electrical connector to the socket. 3. Install the bulb and socket to the housing by rotating the bulb and socket clockwise, locking the retaining tabs to the housing. 4. Install the access cover to the rear of the headlamp assembly 5. Install the headlamp. Page 3888 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 44 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 1555 Tighten the screws to 8 N.m (71 lb in). 5. Fully seat the water deflector to the door. 6. Install the door trim panel. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 2 and SIR Disabling and Enabling Zone 6. Page 561 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 4822 Ignition Coil 2 Page 4694 10.1. Remove the EVAP/fuel hose/pipe assembly retaining bolt (3) from the transmission. 10.2. Remove the EVAP/fuel hose/pipe assembly from the clip at the rear of the transmission. 11. Disconnect the EVAP purge pipe (2) from the EVAP canister (1) . 12. Disconnect the chassis fuel return pipe (1) from the fuel tank fuel return pipe. 13. Disconnect the chassis fuel feed pipe (3) from the fuel filter. 14. Remove the EVAP/fuel hose/pipe assembly. Page 1004 34. Install the coolant bypass valve to its original location and secure with a nut. 35. Connect the other end of the new hose from step 29 to the outlet port of the auxiliary heater pump. 36. Connect the vacuum hose to the coolant bypass valve. 37. Connect the coolant bypass valve hose to the auxiliary rear heater line. 38. Install the heater hose quick connect retainers to the heater core pipes. 39. Connect the remaining two hoses to the heater core. 40. Install the new auxiliary heater pump wiring harness to the vehicle. Page 1269 Low Pressure Sensor / Switch: Locations Engine Compartment, Right Rear (w/Manual HVAC System) Engine Compartment, Right Rear (w/Automatic HVAC System) Page 12788 Page 4068 Page 3590 Engine Control Module: Description and Operation POWERTRAIN CONTROL MODULE (PCM) The PCM verifies that the password received from the theft deterrent control module via the serial data circuit is correct. The PCM can learn only one fuel continue password. If the fuel continue password is correct, the PCM enables the starting and fuel delivery systems. The PCM disables the starting and fuel delivery systems if any of the following conditions occur: - The fuel continue password is incorrect. - The fuel disable password is sent by the theft deterrent control module. - No passwords are received - there is no communication with the theft deterrent control module. The powertrain control module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. The PCM controls all ignition system functions, and constantly corrects the spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Page 13515 Courtesy/Reading Lamp - LR Page 8579 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12844 Abbreviations And Meanings Part 21 Page 9664 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 1846 Steps 20-22 Page 9860 Disclaimer Page 988 Disclaimer Page 10039 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 13149 Abbreviations And Meanings Part 21 Page 4237 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 6354 Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear brake hose bolt from the rear brake caliper. 4. Plug the opening of the brake hose in order to prevent excessive brake fluid loss and contamination. Important: Discard the metal (copper) gaskets. DO NOT reuse metal (copper) gaskets, replace them. 5. Remove the metal (copper) gaskets from the brake hose bolt. 6. Remove the rear brake caliper mounting bolts. Page 8732 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. See: Compressor HVAC/Service and Repair See: Service and Repair/Flushing Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. See: Specifications/Capacity Specifications Page 9533 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 10186 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 9873 4. Remove the electrical connectors from the VCIM. 5. Remove the VCIM from the vehicle INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. 2. Install the module to the upper bracket ensuring the retaining tab is fully seated. 3. Connect the 2 electrical connectors. NOTE: In order to avoid damage to the circuit board, do NOT over-tighten the thumb screws. Using your fingers, apply only a light pressure. Tighten Tighten the module thumb screw to a maximum of 0.2 N.m (2 lb in). Page 13433 16532714 Buick and Oldsmobile --New P/N 16532715 GMC --New P/N 16532716. ^ If the part number printed on a circuit board IS one of the part number listed above, then the circuit board is the new design and does NOT need to be replaced. ^ If the part number printed on a circuit board is NOT one of the part numbers listed above, then the circuit board is the old design and MUST BE REPLACED. Proceed to the next step if either circuit board needs to be replaced. 5. Turn on the tail lamps, directional signals, etc. and determine if there are any bulbs that require replacement. 6. Disconnect the electrical connector from the circuit board being replaced. 7. Remove the three screws attaching the circuit board to the tail lamp and remove the circuit board. 8. Install a NEW stop lamp bulb in a NEW circuit board. ^ On Chevrolet, Buick, and Oldsmobile vehicles, the stop lamp bulb is located in the UPPER (top) socket in the circuit board. ^ On GMC vehicles, the stop lamp bulb is located in the LOWER (bottom) socket in the circuit board. 10. Important: This recall will cover the cost of replacing the stop lamp bulb(s). All other bulbs that require replacement are to be submitted under the normal warranty operation, if applicable. 11. Transfer the remaining bulbs from the old circuit board to the new circuit board. Replace any burned out bulbs. 12. Connect the electrical connector to the new circuit board(s). 13. Turn on the tail lamps, directional signals, etc. and verify that all bulbs are functional. 14. Install the circuit board to the tail lamp and install the three screws. Tighten Tighten the screws to 1.9 Nm (17 lb in). 15. Install both the left and the right tail lamp assemblies to the body and install the screws. Tighten Tighten the screws to 1.9 Nm (17 lb in). 16. Close the liftgate. Specifications Power Steering Fluid: Specifications Fluid Type .......................... GM Power Steering Fluid GM P/N 1052884 - 1 pint (Canadian P/N 993294), 1050017 - 1 quart, (Canadian P/N 992646) or equivalent. Page 6244 Page 10994 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 3935 Abbreviations And Meanings Part 22 Page 4051 1. Install the PCM mounting studs to the intake manifold, if removed. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the studs to 6 N.m (53 lb in). 2. Install the PCM (2) to the intake manifold. 3. Install the PCM mounting nuts and bolts (4). Tighten Tighten the nuts and bolts to 10 N.m (88 lb in). 4. Install the PCM harness connectors (3) to the PCM body. 5. Tighten the PCM harness connector retaining bolts (1). Tighten Tighten the bolts to 8 N.m (71 lb in). 6. If a new PCM is being installed, the PCM must be programmed. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. See: Testing and Inspection/Programming and Relearning Page 8506 HVAC Control Module C1 Part 3 HVAC Control Module C2 Part 1 Page 3509 Abbreviations And Meanings Part 26 Locations Electronic Components Page 9534 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 5706 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Page 10029 Page 7782 4. Connect the upper intermediate shaft to the lower intermediate shaft. 5. Install the upper intermediate shaft to the lower intermediate shaft pinch bolt. Tighten the upper intermediate shaft to the lower intermediate shaft pinch bolt to 50 Nm (37 ft. lbs.). Important: The upper intermediate shaft boot must completely cover the white insert of the lower intermediate shaft boot to ensure proper sealing. 6. Connect the upper intermediate shaft boot to the lower intermediate shaft boot. 7. Install the knee bolster. Unlock the steering column by removing J42640 from the steering column lower trim cover access hole. Locations Sunroof / Moonroof Module: Locations Roof With Headliner Removed Page 12889 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 53 English Prevailing Torque Fastener Minimum Torque Development Part 1 Compressor Hose Assembly Hose/Line HVAC: Service and Repair Compressor Hose Assembly COMPRESSOR HOSE ASSEMBLY REPLACEMENT (BODY VIN TYPE 3) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Remove the compressor hose assembly nut (3). 3. Remove the compressor hose assembly from the compressor (4). 4. Remove the sealing washers. 5. Remove the compressor suction hose nut from the accumulator. 6. Remove the compressor suction hose from the accumulator. 7. Remove the O-ring seal. 8. Remove the bolt from the lift bracket. 9. Remove the nut from the engine stud. 10. Remove the compressor discharge hose (2) from the condenser (4). 11. Remove the nut from compressor hose connection in driver wheel opening. 12. Remove the O-ring seals. 13. Cap or plug all of the open connections. INSTALLATION PROCEDURE Page 13410 Specifications Page 6508 6. Remove the park brake cable from the park brake lever. 7. Slide the park brake shoe (2) down until it is disengaged from the hold down spring (3). 8. Lift the shoe (2) away from the backing plate and slide the shoe up, off of the actuation mechanism (1). 9. Remove the shoe (2) over the axle flange and from the vehicle. 10. Clean the debris and the dust from the park brake components using a clean towel. 11. Turn the adjustment screw to the fully home position in the notched adjustment nut, then back it off 1/4 turn. 12. Align the slots in both the adjusting screw and tappet to be parallel with the backing plate face. 13. Using denatured alcohol, clean the rear backing plate of dirt and foreign materials. 14. Using non-lubricated, filtered air, dry the backing plate. Installation Procedure 1. Install a new park brake shoe (2) over the axle flange. Page 6552 Chassis Harness, Frame-Left Side Page 12441 1.1. Align the trim panel to the seat assembly. 1.2. Install the screws retaining the trim panel to the seat assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the trim panel screws to 3 N.m (26 lb in). 1.3. Install the 3 seat switch bezel mounting screws. Tighten Tighten the seat switch bezel mounting screws to 3 N.m (26 lb ft). 2. Install the trim panel to the manual seat by performing the following steps: 2.1. Install the screws in the trim panel. 2.2. Install the lumbar support knob. 2.3. Install the seat back recliner handle. Seat Cushion Cover and Pad Replacement - Front SEAT CUSHION COVER AND PAD REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the 3 seat switch bezel screws. Page 4688 Page 4224 Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION ACCIDENT WITH OR WITHOUT INFLATOR MODULE DEPLOYMENT - COMPONENT INSPECTIONS CAUTION: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. - Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than intended. - The steering column - Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection in Steering. - The IP knee bolsters and mounting points - Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. - The IP brackets, braces, etc. - Inspect for bending, twisting, buckling, or any other type of damage. - The seat belts - Perform the seat belt operational and functional checks. Refer to Operational and Functional Checks in Seat Belts. - The IP cross car beam - Inspect for bending, twisting, buckling, or any other type of damage. - The IP mounting points and brackets - Inspect for bending, twisting, buckling, or any other type of damage. - The seats and seat mounting points - Inspect for bending, twisting, buckling, or any other type of damage. ACCIDENT WITH FRONTAL AIR BAG DEPLOYMENT - COMPONENT REPLACEMENT AND INSPECTIONS After a collision involving air bag deployment, replace the following components. Inflatable restraint IP module - Inflatable restraint steering wheel module - Inflatable restraint steering wheel module coil - Inflatable restraint sensing and diagnostic module (SDM) - Inflatable restraint electronic frontal sensor (EFS) (if equipped with dual stage air bags) Perform additional inspections on the following components. Steering wheel module coil and the coil wiring pigtail - Inspect for melting, scorching, or other damage due to excessive heat. - Mounting points or mounting hardware for the IP module, steering wheel module, SDM, and EFS sensor (if equipped with dual stage air bags) - Inspect for any damage and repair or replace each component as needed. ACCIDENT WITH SIDE AIR BAG DEPLOYMENT - COMPONENT REPLACEMENT AND INSPECTIONS After a collision involving side air bag deployment, replace the following components. Inflatable restraint side impact sensors (SIS) (Left/Right), on the side of the impact. - Inflatable restraint side impact module (LF/RF), on the side of the impact. - Inflatable restraint sensing and diagnostic module (SDM). Perform additional inspections on the following components. Mounting points or mounting hardware for the SIS, and side impact module (LF/RF) on the side of impact - Inspect for any damage and repair or replace each component as needed. - Mounting points or mounting hardware for the SDM - Inspect for any damage and repair or replace each component as needed. SENSOR REPLACEMENT GUIDELINES The SIR/side air bag sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. An example of this would be a moderate collision where the front of the vehicle impacts a tree, if the vehicle has an SIR sensor mounted forward of the radiator, replace the SIR sensor. Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if the sensor appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR/side air bag sensing system. Do not try to determine whether the sensor is undamaged. Replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Page 12171 Abbreviations And Meanings Part 16 Page 10614 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 7816 5. Loosen the jam nut (1) and remove the outer tie rod (2) from the inner tie rod (3). Do not reuse the jam nut. 6. Inspect the shaft for bent or damaged threads. 7. Clean the tapered surface of the steering knuckle. Installation Procedure 1. Lubricate the inner tie rod (3) threads with a suitable chassis lubricant before installing the outer tie rod (2). 2. Install the new jam nut (1) to the outer tie rod (2). 3. Install the outer tie rod (2) to the inner tie rod (3). OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Body - Door(s) Are Difficult To Close Rear Door Striker: Customer Interest Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Page 9167 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 8294 2. Disconnect the electrical connector (2) from the air temperature sensor-upper right (1). 3. Remove the air temperature sensor-upper right (1) by turning the sensor clockwise and pulling out. INSTALLATION PROCEDURE 1. Install the air temperature sensor-upper right (1). 2. Connect the electrical connector (2) to the air temperature sensor-upper right (1). 3. Install the radio. Page 3370 Engine Coolant Temperature (ECT) Sensor Page 7482 C306 Page 1343 Headlamp Switch: Diagrams Headlamp Switch C1 Part 1 Page 10011 Page 12232 Memory Seat Module - Passenger C1 Page 6912 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 8175 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 8055 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 2884 Specifications Thermostat: Specifications Temperature Range ............................................................................................................................ ...................................... 87°C (188°F) - 97°C (206°F) Page 6462 11. Install the master cylinder to the vehicle. Refer to Master Cylinder Replacement. Page 3914 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 2925 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 9814 Abbreviations And Meanings Part 6 Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 11844 Registered And Non-Registered Trademarks Part 3 Locations Accelerator Description and Operation Oil Change Reminder Lamp: Description and Operation GM OIL LIFE SYSTEM Your vehicle has a computer system that lets you know when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change will be indicated can vary considerably. For the oil life system to work properly, you must reset the system every time the oil is changed. When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. Either a "CHANGE ENGINE OIL" message in the Driver Information Center (DIC) or a CHANGE OIL indicator will come on. Change your oil as soon as possible within the next two times you stop for fuel. It is possible that, if you are driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, your engine oil and filter must be changed at least once a year and at this time the system must be reset. It is also important to check your oil regularly and keep it at the proper level. If the system is ever reset accidentally, you must change your oil at 3,000 miles (5 000 km) since your last oil change. Remember to reset the oil life system whenever the oil is changed. Page 946 Engine Control Module: Diagrams Powertrain Control Module (PCM) C2 Powertrain Control Module (PCM) C2 Part 1 Page 3472 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 12871 Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Press tabs (1) inward and lift to remove the junction block cover. 3. Pull upward on the fuse relay center cover (1) to release the retaining tabs and remove the cover. 4. Note the location and remove the harness end bolts (2) and remove the harness ends from the fuse relay center. 5. Remove the fuse relay center bolts (3) and remove the fuse relay center from the junction block bracket. 6. Pull downward on the wiring harness ends to remove from the bottom of the fuse relay center. Page 7486 C308 Page 9966 Page 87 Registered And Non-Registered Trademarks Part 6 A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Page 4281 Abbreviations And Meanings Part 15 Page 12489 Page 4575 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Page 13008 Abbreviations And Meanings Part 9 Page 13908 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 11668 16. Install the center pillar headliner harness electrical connector to the bussed electrical center, and the block base to the floor panel. 17. Install the headliner harness retaining clips (2) to the rocker panel and the floor panel. 18. Install the headliner harness to the left center pillar. 19. Install the following headliner harness clips to the center pillar: * The center pillar harness clips (1) * The center pillar harness clips (3) * The center pillar harness clips (4) Notice: Refer to Fastener Notice in Service Precautions. 20. Install the ground terminals and the ground bolt (2) to the center pillar. Tighten the bolt to 10 N.m (88 lb in). 21. If equipped with OnStar(R) perform the following procedure: 1. Install the navigation antenna cable to the right center pillar. 2. Install the navigation antenna cable to the right side door sill attachments. 3. Install the navigation antenna cable to the communication interface module. 22. Install the sunshades to the headliner. 23. If equipped, install the front and rear overhead console. Refer to Overhead Console Replacement - Front, or to Overhead Console Replacement Rear. 24. Install the video display. 25. Install the windshield garnish moldings. 26. Install the center pillar trim panels. 27. Install the rear side door sill plates. 28. Install the front side door sill plates. 29. Install the rear seats. 30. Install the luggage/cargo shelf assembly, if equipped. 31. Install the cargo net, if equipped. Page 3866 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Specifications Engine Block Heater: Specifications Heater Inlet Fitting 33 ft. lbs. Heater Outlet Fitting 33 ft. lbs. Coolant Heater 37 inch lbs. Page 3965 3. Connect the 24-way gray electrical connector (1) to the BCM. 4. Connect the 32-way tan electrical connector (2) to the BCM. 5. Connect the 40-way body wiring extension (1) to the BCM. 6. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. Page 13151 Abbreviations And Meanings Part 23 Page 434 Page 852 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 10665 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Specifications Brake Bleeding: Specifications Brake System Pressure Bleed Initial Pressure Adjustment Setting, Leak 10 psi Testing the Hydraulic Brake System. Pressure Bleed Procedure Setting 35 psi Buckle Replacement - Front Seat Belt Buckle: Service and Repair Buckle Replacement - Front REMOVAL PROCEDURE 1. Remove the front seat assembly. 2. Disconnect the seat belt reminder wiring harness (3) on the driver's seat. 3. Remove the nut (1) which retains the seat belt buckle to the seat assembly. 4. Remove the seat belt buckle from the seat assembly. INSTALLATION PROCEDURE 1. Install the seat belt buckle to the seat assembly. 2. Install the nut (1) which retains the seat belt buckle to the seat assembly. NOTE: Refer to Fastener Notice in Service Precautions. Wheels/Tires - Recommended Wheel Nut Torque Wheel Fastener: All Technical Service Bulletins Wheels/Tires - Recommended Wheel Nut Torque File In Section: 03 Suspension Bulletin No.: 02-03-10-008 Date: December, 2002 INFORMATION Subject: Recommended Wheel Nut/Bolt Torque Specifications Models: 2003 Passenger Cars and Light Duty Trucks 2003 HUMMER H1, H2 This bulletin is being issued to list the recommended wheel nut/bolt torque specifications for passenger cars and light duty trucks for the 2003 model year. Disclaimer Page 1469 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 9184 Abbreviations And Meanings Part 17 Page 12386 Position Sensor - Horizontal Motor (w/Memory) Page 821 Page 865 Abbreviations And Meanings Part 10 Page 2250 Application Table Part 1 Page 13682 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition contained in this bulletin are to be submitted by August 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle Page 3931 Abbreviations And Meanings Part 18 Page 6179 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 10850 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 13509 Cornering Lamp: Description and Operation CORNERING LAMPS The turn signal switch sends battery positive voltage to the cornering lamps which will constantly remain illuminated until turn signal operation is cancelled. The cornering lamps are grounded at G103 and G107. Page 5778 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13220 Page 2817 Abbreviations And Meanings Part 15 Page 8400 Abbreviations And Meanings Part 20 Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 3012 Important: Every seventh link of the timing chain is darkened to aid in aligning the timing marks. 1. Install the timing chain tensioner and secure the tensioner with the bolts. Tighten the timing chain tensioner bolts to 25 Nm (18 ft. lbs.). 2. Install the timing chain tensioner guide and secure the guide with the bolts. Tighten the timing chain tensioner guide to 10 Nm (89 inch lbs.). 3. Install the timing chain tensioner shoe and secure the shoe with the bolt. Tighten the timing chain tensioner shoe bolt to 26 Nm (19 ft. lbs.). Page 878 Abbreviations And Meanings Part 23 Page 1459 Accelerator Pedal Position (APP) Sensor Page 2623 Valve Cover: Service and Repair Camshaft Cover Replacement Removal Procedure 1. Remove the intake manifold. 2. Discharge the A/C. 3. Remove the A/C line at the oil level indicator tube bracket nut. 4. Remove the A/C line from the accumulator. 5. Remove the A/C bracket bolt from the engine lift hook. 6. Remove the engine lift bracket. 7. Disconnect the ignition control module electrical connectors. 8. Loosen and remove the ignition control module bolts. Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Press tabs (1) inward and lift to remove the junction block cover. 3. Pull upward on the fuse relay center cover (1) to release the retaining tabs and remove the cover. 4. Note the location and remove the harness end bolts (2) and remove the harness ends from the fuse relay center. 5. Remove the fuse relay center bolts (3) and remove the fuse relay center from the junction block bracket. 6. Pull downward on the wiring harness ends to remove from the bottom of the fuse relay center. Page 7598 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 1714 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 6877 Conversion - English/Metric Part 2 Page 3681 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 13903 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 12524 Conversion - English/Metric Part 2 Page 9764 Locations Engine Page 7847 Control Arm: Service and Repair Rear Suspension Rear Axle Upper Control Arm Replacement Rear Axle Upper Control Arm Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheelhouse panel. 4. Raise and support the rear axle at the designed D - height. 5. If equipped with air suspension, Repressurize the air suspension system. 6. If equipped with air suspension, disconnect the air suspension leveling sensor link from the rear axle upper control arm. 7. Remove the rear axle upper control arm to axle mounting bolt and nut. Page 12022 WA765J/37 - WA800J/98 Ambient Air Temperature Sensor Replacement Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the front grille. 2. Remove the sensor (1) from the panel assembly (2). 3. Disconnect the electrical connector from the sensor (1). INSTALLATION PROCEDURE 1. Position the sensor to the panel assembly. 2. Connect the electrical connector to the sensor (1). Page 8600 Evaporator Core: Service and Repair Evaporator Core Replacement EVAPORATOR CORE REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Housing Assembly HVAC/Service and Repair 2. Remove the screws to separate the HVAC module assembly halves. IMPORTANT:Some screws are hidden under the foam insulation. 3. Separate the HVAC module assembly (1). 4. Remove the evaporator core (2) from the HVAC module assembly (1). 5. Remove the seal between the HVAC module assembly halves. INSTALLATION PROCEDURE 1. Install the seal between the HVAC module assembly halves. IMPORTANT:If replacing the evaporator core, add the refrigerant oil to the evaporator core. Refer to Refrigerant System Capacities for system capacity information. 2. Install the evaporator core (2) to the HVAC module assembly (1). 3. Assemble the HVAC module assembly. IMPORTANT:Ensure that the seal between the two case sections is in place. 4. Install the screws to join the HVAC module assembly halves. Page 9867 IMPORTANT: Ensure the inner and outer antenna couplings are aligned. - Do not touch the adhesive backing on the antenna coupling. 1. Align the outer antenna coupling to the inner antenna coupling. 2. Press firmly on all 4 corners and on the center of the antenna outer coupling (2) in order to ensure proper adhesion to the back glass (4). Hold pressure on the outer coupling (5) for 10-30 seconds. 3. Ensure that no gaps are present between the couplings (5, 2) and the back glass (4). Page 4397 Crankshaft Position (CKP) Sensor Page 12267 Luggage Rack: Service and Repair Luggage Carrier Rivnut Replacement Luggage Carrier Rivnut Replacement Removal Procedure 1. Remove the luggage carrier. Caution: Refer to Safety Glasses Caution in Service Precautions. 2. Drill through the luggage carrier rivnut head using a 7.5 mm (0.295 in) drill bit. 3. Remove the rivnut from the roof. Installation Procedure 1. Using a 10 mm (0.3937 in) drill bit, drill the rivnut hex shape hole in the roof out to a round 10 mm hole. 2. Install a replacement rivnut to the hole in roof using a rivnut tool, or equivalent. 3. Install the luggage carrier. Page 4061 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Recall 05V198000: Flasher Module Replacement Hazard Warning Flasher: All Technical Service Bulletins Recall 05V198000: Flasher Module Replacement MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2004 Chevrolet/Trailblazer 2003-2004 GMC/Envoy 2003-2004 Isuzu/Ascender 2003-2004 Oldsmobile/Bravada 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V198000 RECALL DATE: April 29, 2005 COMPONENT: Exterior Lighting: Turn Signal POTENTIAL NUMBER OF UNITS AFFECTED: 286478 SUMMARY: On certain trucks and sport utility vehicles, the driver wishing to signal a turn by moving the directional signal lever, (up or down) may cause the front marker/turn lights and rear turn lights to flash in a manner similar to hazard warning, rather than flashing on the desired side only. CONSEQUENCE: The driver may not be able to clearly signal their intentions to turn, change travel lanes, or potentially warn others of an impaired vehicle operating condition increasing the risk of a crash. REMEDY: Dealers will replace the suspect flasher modules with a new flasher module designed with sealed relays and more durable contact material inside of the relays. The recall is expected to begin during August 2005. owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727, Buick at 1-866-608-8080, and Oldsmobile at 1-800-630-6537. NOTES: GM recall No. 05044. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Page 7222 Page 10140 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 9779 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 7221 Page 442 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Camshaft Actuator System Camshaft Position Sensor: Description and Operation Camshaft Actuator System CAMSHAFT POSITION (CMP) ACTUATOR SYSTEM The Camshaft Position Actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation control, a wider engine torque range, improved gas millage, and improved engine idle stability. The CMP Actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. CMP ACTUATOR SYSTEM OPERATION The CMP Actuator system is controlled by the Powertrain Control Module (PCM). The PCM sends a pulse width modulated 12 volt signal to a Camshaft Position (CMP) Actuator Solenoid in order to control the amount of engine oil flow to a cam Phaser passage. There are two different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The Cam Phaser is attached to a camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position. Engine oil pressure, viscosity, temperature and engine oil level can have an adverse affect on cam phaser performance. The PCM calculates the optimum cam position through the following inputs: Engine Speed - Manifold Absolute Pressure (MAP) - Throttle Position (TP) Indicated Angle - Crankshaft Position (CKP) - Camshaft Position (CMP) - Engine Load. - Barometric (BARO) Pressure The Cam Phaser default position is 0 degrees. The PCM uses the following inputs before assuming control of the cam phaser: Engine Coolant Temperature (ECT) - Closed Loop Fuel Control - Engine Oil Temperature - Engine Oil Pressure - Engine Oil Level - CMP Actuator Solenoid circuit state - Ignition 1 signal voltage - Barometric (BARO) Pressure CMP ACTUATOR SOLENOID CIRCUIT DIAGNOSTICS The PCM monitors the control circuits of the CMP Actuator Solenoid for electrical faults. The PCM has the ability to determine if a control circuit is open, shorted high, and shorted low. If the PCM detects a fault with a CMP Actuator Solenoid circuit a Diagnostic Trouble Code (DTC) will set. CMP ACTUATOR SYSTEM PERFORMANCE DIAGNOSTICS The PCM monitors the performance of the CMP Actuator system by monitoring the actual and desired positions of a cam phaser. If the difference between the actual and desired position is more than a calibrated angle for more than a calibrated amount of time, a DTC will set. Page 7531 Location View OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 2779 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 11061 Front Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Front Door Tools Required J 36796 Clip Removal Tool Removal Procedure 1. Remove the accessory switch panel. 2. Remove the 2 trim panel retaining bolts. 3. Use the J 36796 in order to release the 9 trim panel fasteners from the door. 4. Remove the trim panel from the door. 5. Remove the inside door handle bezel. 6. Remove the outside rear view mirror (ORVM) switch, if equipped. Installation Procedure 1. Install the ORVM switch, if equipped. 2. Install the inside door handle bezel. 3. Install the door trim panel to the door, as follows: 1. Install the panel on the door by placing the upper flange into the belt seal lip. 2. Install the rear upper retainer first. 3. Install the forward upper retainer second. 4. Install the remaining seven retainers. 5. Install the forward trim panel retaining bolt first. Do not tighten the bolt. 6. Install the rearward trim panel retaining bolt second. 7. Tighten the two retaining bolts. Notice: Refer to Fastener Notice in Service Precautions. Tighten the bolts to 10 N.m (88 lb in). 4. Install the accessory switch panel. Page 8901 11. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 12. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 13. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 14. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 9 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 1749 Abbreviations And Meanings Part 13 Page 3459 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 14024 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 12942 Registered And Non-Registered Trademarks Part 5 Page 7431 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 4439 Oil Pressure Sensor: Diagrams Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Page 7778 For vehicles repaired under warranty, use the table. Disclaimer Page 7462 C104 Part 2 C105 Part 1 Page 13093 Page 6314 Brake Rotor/Disc: Service and Repair Brake Rotor Refinishing Brake Rotor Refinishing ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Important: Do NOT refinish the brake rotors in order to correct any of the following complaints: ^ Growl or squeal brake noise ^ Premature brake lining wear ^ Cosmetic or superficial corrosion of the rotor braking surface ^ Rotor discoloration Refinish the brake rotors ONLY when one or more of the following conditions exist: ^ Groove depth in excess of specification ^ Severe scoring of the rotor braking surface ^ Brake pulsation caused by the following: ^ Lateral runout in excess of specification ^ Brake rotor thickness variation in excess of specification ^ Corrosion or pitting that is deeper than the rotor braking surface 1. Use the J 42450-A in order to clean the wheel bearing/hub. 2. Use a micrometer in order to measure the thinnest point of the brake rotor. If the thinnest point of the brake rotor exceeds the brake rotor minimum thickness, do NOT refinish the brake rotor. Replace the brake rotor. 3. Use the J 41013 in order to THOROUGHLY clean the rust from the brake rotor flange. 4. Refinish the brake rotor. Refer to the brake lathe manufacturer's operating instructions. Important: Failure to obtain the best possible braking surface finish may cause the vehicle to stop with difficulty. 5. After machining the rotor, use 120 grit aluminum oxide sandpaper and a non-directional rotor finisher, if available, in order to create a non-directional braking surface. 6. Clean the braking surfaces with GM P/N 12377981, Canadian P/N 10953463, or equivalent brake parts cleaner. Page 2896 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 12800 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 10202 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 12975 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Brakes - Revised Caliper Mounting Bolt Torque Spec. Brake Caliper: Technical Service Bulletins Brakes - Revised Caliper Mounting Bolt Torque Spec. Bulletin No.: 03-05-23-002A Date: April 26, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Brake Caliper Bracket Mounting Bolt Fastener Tightening Specification Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer Models 2004-2005 Chevrolet SSR 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add models, model years and update the fastener tightening specification. Please discard Corporate Bulletin Number 03-05-23-002 (Section 05 - Brakes). This bulletin is being issued to revise the front brake caliper bracket mounting bolt fastener tightening specification in the Disc Brakes sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The correct fastener tightening specification for the front brake caliper bracket mounting bolt is 150 N.m (110 lb ft). Disclaimer Service and Repair Power Steering Bleeding: Service and Repair Bleeding the Power Steering System Tools Required ^ J35555 Metal Mityvac ^ J43485 Power Steering Bleeder Adapter Important: Hoses touching the frame, body, or engine may cause system noise. 1. Verify that the hoses do not touch any other part of the vehicle. Important: Loose connections may not leak, but could allow air into the steering system. 2. Verify that all hose connections are tight. Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Important: Maintain the fluid level throughout the bleed procedure. 3. Remove the pump reservoir cap. Important: Use clean, new power steering fluid only. 4. Fill the pump reservoir with fluid to the FULL COLD level. 5. Attach the J43485 to the J35555 or equivalent. 6. Place the J43485 on or in the pump reservoir filler neck. 7. Apply a vacuum of 68 kPa (20 in Hg) maximum. 8. Wait 5 minutes. Typical vacuum drop is 7 - 10 kPa (2 - 3 in Hg). If the vacuum does not remain steady, refer to Excessive Vacuum Drop Diagnosis. 9. Remove the J43485 and the J35555. 10. Reinstall the pump reservoir cap. Page 2177 6. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 7. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 8. Disconnect the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 9. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 10. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Page 9490 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 6996 Fuse Block: Application and ID Underhood Fuse Block Location View Application Table Part 1 Page 224 Page 2552 17. Remove trim tool assembly EN 45680-411 from the engine block. 18. Remove any material shavings that may be found on the metal shaving catch plug EN 45680-413. 19. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the metal shaving catch plug EN 45680-413. 20. Install a straight edge on the cylinder block perpendicular to the crankshaft center line. 21. Using a light, illuminate the backside of the straight edge. 22. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present of either side or both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed. 23. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly. 24. Proceed to the next cylinder bore sleeve to be trimmed repeating steps 10-23 if necessary. Parts Information Page 196 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 1006 40.5. Route the other end of the harness along the rear of the engine compartment to the left side and secure to the cross bar and dash panel with tie straps. Page 13277 Abbreviations And Meanings Part 15 Page 10156 Page 7136 Location View Page 11845 Registered And Non-Registered Trademarks Part 4 Page 4173 Steps 20-22 Page 12628 Seat Adjuster Switch - Driver (w/Memory) Page 11670 21. Remove the following headliner harness clips from the left center pillar: * The center pillar harness clips (4) * The center pillar harness clips (3) * The center pillar harness clips (1) 22. Remove the center pillar harness ground bolt (2). 23. Remove the harness from the left center pillar. 24. Remove the rear seats. 25. Remove the headliner harness retaining clips (2) from the rocker panel and floor panel. 26. Remove the center pillar headliner harness electrical connector from the bussed electrical center, and the block base from the floor panel. 27. Reach underneath the carpet and remove the headliner harness electrical connector (1) from the IP wire harness. 28. Disconnect the inside rear view mirror electrical connector (6). 29. Disconnect the rain sensor electrical connector, if equipped. 30. Disconnect the navigation antenna electrical connector, if equipped. 31. Remove the upper rear quarter trim panels. 32. Remove the coat hooks from the roof panel. 33. Disconnect the radio control module electrical connector from the right body side window. 34. Disconnect the radio antenna module electrical connector from the left body side window. 35. Disconnect the electrical connector from the cellular phone antenna. 36. Remove the 2 push pins from the rear of the headliner. 37. Release the assist handles from the roof panel. Refer to Assist Handle Replacement. 38. Fully recline the bucket seats. 39. With the aid of an assistant, release the interlocking strips (1) that retain the headliner to the roof panel. Page 3948 Body Control Module (BCM) C1 Part 2 Page 24 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 10556 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 8520 Control Assembly: Service and Repair HVAC System - Manual Primary HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP accessory trim plate. 2. Remove the control module retaining screws. 3. Depress the HVAC control module retaining tabs (3) and remove the HVAC control module (2) from the instrument panel (4). 4. Disconnect the electrical connectors (1) from the HVAC control module (2). INSTALLATION PROCEDURE 1. Connect the electrical connectors to the HVAC control module (2). IMPORTANT:The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. Page 4042 Powertrain Control Module (PCM) C2 Part 4 Page 3854 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. 2. Install the APP sensor retaining fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 7228 Page 13607 Turn Signal/Hazard Flasher Module Part 2 Page 12966 Cigarette Lighter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 417 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 6237 Brake Warning Indicator: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Hydraulic System Testing and Inspection. Page 13984 Steps 13-17 Locations Engine, Left Side Page 13409 16532714 Buick and Oldsmobile --New P/N 16532715 GMC --New P/N 16532716. ^ If the part number printed on a circuit board IS one of the part number listed above, then the circuit board is the new design and does NOT need to be replaced. ^ If the part number printed on a circuit board is NOT one of the part numbers listed above, then the circuit board is the old design and MUST BE REPLACED. Proceed to the next step if either circuit board needs to be replaced. 5. Turn on the tail lamps, directional signals, etc. and determine if there are any bulbs that require replacement. 6. Disconnect the electrical connector from the circuit board being replaced. 7. Remove the three screws attaching the circuit board to the tail lamp and remove the circuit board. 8. Install a NEW stop lamp bulb in a NEW circuit board. ^ On Chevrolet, Buick, and Oldsmobile vehicles, the stop lamp bulb is located in the UPPER (top) socket in the circuit board. ^ On GMC vehicles, the stop lamp bulb is located in the LOWER (bottom) socket in the circuit board. 10. Important: This recall will cover the cost of replacing the stop lamp bulb(s). All other bulbs that require replacement are to be submitted under the normal warranty operation, if applicable. 11. Transfer the remaining bulbs from the old circuit board to the new circuit board. Replace any burned out bulbs. 12. Connect the electrical connector to the new circuit board(s). 13. Turn on the tail lamps, directional signals, etc. and verify that all bulbs are functional. 14. Install the circuit board to the tail lamp and install the three screws. Tighten Tighten the screws to 1.9 Nm (17 lb in). 15. Install both the left and the right tail lamp assemblies to the body and install the screws. Tighten Tighten the screws to 1.9 Nm (17 lb in). 16. Close the liftgate. Page 13990 5. Connect the electrical connector. 6. Test the grid line operation in order to verify the grid line repair. Rear Window Defogger Braided Lead Wire REAR WINDOW DEFOGGER BRAIDED LEAD WIRE 1. Use a solder containing 3 percent silver and a rosin flux paste in order to solder and attach the rear defogger bus bar lead wire and/or defogger terminal. CAUTION: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. 2. Buff the repair area with a fine steel wool in order to remove the oxide coating that was formed during window manufacture. 3. Use a brush in order to apply the paste-type rosin flux in small quantities to the appropriate area: - The rear defogger bus bar lead wire - The defogger terminal repair area 4. Coat the solder iron tip with solder. Apply only enough heat to melt the solder and only enough solder to ensure a complete repair. CAUTION: Refer to Window Retention Caution in Service Precautions. IMPORTANT: Do not hold the tool in one spot or operate the tool on the window for longer than 30-40 seconds. If the window becomes hot to the touch, allow the window to air cool before proceeding further. Cooling with water may crack the heated window. Avoid excessive pressure in order to ensure that the window will not overheat. 5. Apply the solder to the feed bus bar or the ground bus bar. Draw the soldering iron tip across the fluxed area. Thinly coat the bus bar with solder. 6. Apply a small amount of flux to the appropriate areas: - The underside of the rear defogger bus bar lead wire - The defogger terminal 7. Align the spots with the flux to the appropriate areas: - The underside of the rear defogger bus bar lead wire - The defogger terminal 8. Coat the tip of the soldering iron with solder. 9. Solder the appropriate areas: - The underside of the rear defogger bus bar lead wire - The defogger terminal 10. Draw the iron across the fluxed spot. Thinly coat the spot with solder. 11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar. 12. Use pliers in order to hold the appropriate component: - The rear defogger bus bar lead wire - The defogger terminal 13. Apply heat to the appropriate area in order to ensure the solder spot melts and fuses together: - The top of the rear defogger bus bar lead wire - The defogger terminal 14. Remove the excess flux with the solvent. IMPORTANT: Do not remove the holding force until the solder has solidified. 15. Connect the electrical connector. Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 9769 Page 3962 Body Control Module: Removal and Replacement Body Control Module Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the BCM on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. Page 7338 Fuse Block - Rear C2 Part 7 Fuse Block - Rear C3 Part 1 Page 7538 12. Disconnect the body wiring harness connector (1) from the junction block. 13. Disconnect the headliner harness connector (2) from the junction block. 14. Disconnect the console harness connector from the junction block. 15. Remove the block base retaining nuts from the floor studs. 16. Remove the block base from the floor panel. INSTALLATION PROCEDURE 1. Install the block base to the floor studs. 2. Install the block base retaining nuts to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the block base retaining nuts to 10 N.m (88 lb in). 3. Connect the console harness connector to the block base. 4. Connect the headliner harness connector (2) to the block base. 5. Connect the body wiring harness connector (1) to the block base. Page 4253 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 2725 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Remove the oil fill cap. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the oil pan drain plug and drain the oil into a suitable container. Important: 0mCheck the old oil filter to ensure the filter seal is not left on the engine block. 4. Remove the oil filter using a suitable wrench. 5. Wipe the excess oil from the oil filter housing. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the new oil filter. Tighten the oil filter to 17 Nm (22 ft. lbs.) plus 150°. 3. Install the oil pan drain plug. Tighten the oil pan drain plug to 26 Nm (19 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. Page 8382 Abbreviations And Meanings Part 2 Page 8652 Minimum Tube Length Required Table IMPORTANT:When sectioning the rear A/C or heater lines, ensure that the correct minimum length remains in the straight part of the line on both sides of the splice. Follow the Straight Line Repair procedure in order to repair line damage in a straight section of line. Follow the Line Sectioning Repair procedure in order to repair any damage in a bend area. Do not repair the rear A/C or heater lines in a bend area, replace the lines. Maintaining the original line shape will prevent vibrations and rub-through. Line Sectioning Repair 1. Recover the refrigerant, if repairing the A/C lines. 2. Drain the coolant, if repairing the heater lines. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Obtain a new A/C or heater line for sectioning. 5. Scribe a mark on the line that will be sectioned. IMPORTANT:Stagger the splices if repairing more than one line. 6. Use a tubing cutter in order to cut the line or lines being replaced. 7. Remove the section of line being replaced from the vehicle. 8. Install the replacement line to the vehicle. IMPORTANT:The length of the replacement line must be the same as the line being replaced. 9. Use a tubing cutter in order to cut the replacement line to length. 10. Use the cleaning pad from the J 41425 in order to clean any burrs or grease. Be sure to clean at least 19 mm (0.75 in) from the line splice area. 11. Use the LOK prep sealant in order to prep the line ends. 12. Apply one drop of the J 41425-3 sealing compound to the outside of each line end. 13. Insert the line ends into the LOK fitting. 14. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 15. Install the correct LOK fitting jaws into the J 41425-1 tool. 16. Install the J 41425-1 tool over the LOK connectors.Verify that the LOK connector ends are positioned in the counter bores of the jaws. 17. Hold the tool body with a 3/8" breaker bar. Turn the forcing screw until both of the connector collars bottom on the center shoulder of the LOK fitting. 18. Loosen the forcing screw. Remove the tool from the repaired line. 19. Verify that the LOK fitting is correctly installed. 20. Lower the vehicle. 21. Refill the coolant, if drained. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 22. Evacuate and recharge the refrigerant, if repairing the A/C lines. Page 9549 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 8924 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 8. CAUTION: Refer to SIR Caution in Service Precautions. 2. Remove the floor console. 3. Partially remove the console mounting bracket in order to allow access to the rear carpet. Refer to Bracket Replacement - Console Floor in Instrument Panel, Gages, and Console. 4. Position the rear carpet in order to access the sensing and diagnostic module (SDM). 5. Disconnect the electrical connectors (2) from the SDM (1). 6. Remove the nuts that retain the SDM to the floor panel. 7. Remove the SDM from the vehicle. Installation Procedure Brake Caliper Bracket Replacement Brake Caliper: Service and Repair Brake Caliper Bracket Replacement Front Brake Caliper Bracket Replacement - Front Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Inspect the brake caliper assembly. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 4. Remove the front brake caliper assembly, relocate the brake caliper to the side. 5. Inspect the brake pads. 6. Remove the front brake pads from the mounting bracket, inboard brake pad shown. 7. Inspect the brake hardware. Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: All Technical Service Bulletins Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 11848 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 2093 Fluid - Differential: Service and Repair Lubricant Replacement - Rear Drive Axle Lubricant Replacement - Rear Drive Axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Inspect the rear axle for leaks. Repair as necessary. 3. Clean the area around the rear axle fill plug. 4. Remove the rear axle fill plug. 5. Remove the rear axle drain plug. 6. Drain the lubricant into a suitable container. 7. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 8. Clean the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Page 838 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Camshaft Actuator System Camshaft Position Sensor: Description and Operation Camshaft Actuator System CAMSHAFT POSITION (CMP) ACTUATOR SYSTEM The Camshaft Position Actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation control, a wider engine torque range, improved gas millage, and improved engine idle stability. The CMP Actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. CMP ACTUATOR SYSTEM OPERATION The CMP Actuator system is controlled by the Powertrain Control Module (PCM). The PCM sends a pulse width modulated 12 volt signal to a Camshaft Position (CMP) Actuator Solenoid in order to control the amount of engine oil flow to a cam Phaser passage. There are two different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The Cam Phaser is attached to a camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position. Engine oil pressure, viscosity, temperature and engine oil level can have an adverse affect on cam phaser performance. The PCM calculates the optimum cam position through the following inputs: Engine Speed - Manifold Absolute Pressure (MAP) - Throttle Position (TP) Indicated Angle - Crankshaft Position (CKP) - Camshaft Position (CMP) - Engine Load. - Barometric (BARO) Pressure The Cam Phaser default position is 0 degrees. The PCM uses the following inputs before assuming control of the cam phaser: Engine Coolant Temperature (ECT) - Closed Loop Fuel Control - Engine Oil Temperature - Engine Oil Pressure - Engine Oil Level - CMP Actuator Solenoid circuit state - Ignition 1 signal voltage - Barometric (BARO) Pressure CMP ACTUATOR SOLENOID CIRCUIT DIAGNOSTICS The PCM monitors the control circuits of the CMP Actuator Solenoid for electrical faults. The PCM has the ability to determine if a control circuit is open, shorted high, and shorted low. If the PCM detects a fault with a CMP Actuator Solenoid circuit a Diagnostic Trouble Code (DTC) will set. CMP ACTUATOR SYSTEM PERFORMANCE DIAGNOSTICS The PCM monitors the performance of the CMP Actuator system by monitoring the actual and desired positions of a cam phaser. If the difference between the actual and desired position is more than a calibrated angle for more than a calibrated amount of time, a DTC will set. Page 8073 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 12402 Seat Adjuster Switch - Driver (w/Memory) Page 3956 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Description and Operation Fan Shroud: Description and Operation Air Baffles and Seals The cooling system uses deflectors, air baffles and air seals to increase cooling system capability. Deflectors are installed under the vehicle to redirect airflow beneath the vehicle and through the radiator to increase engine cooling. Air baffles are also used to direct airflow through the radiator and increase cooling capability. Air seals prevent air from bypassing the radiator and A/C condenser, and prevent recirculation of hot air for better hot weather cooling and A/C condenser performance. Body - Rattle from Front of Vehicle Hood Latch: All Technical Service Bulletins Body - Rattle from Front of Vehicle Bulletin No.: 03-08-63-003 Date: December 04, 2003 TECHNICAL Subject: Rattle From Front of Vehicle (Adjust Hood Latch Following New Procedure) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on a rattle coming from the front of their vehicle. Cause The hood latch may have been improperly adjusted. Correction Adjust the hood latch following the procedure below. 1. Open the hood and insert the prop rod. 2. Remove the grille. Refer to Grille Replacement in SI. 3. Remove the left and right adjustable rubber bumpers. 4. Return the prop rod to its secured position and close the hood in a normal manner, engaging the primary latch. 5. Loosen all three hood latch bolts. 6. Inspect the left and right side hood fit to the fender. Assure that the hood is at a minimum of 2 mm (0.078 in) below the fenders on both sides. Apply downward pressure to the center of the hood above the latch in order to gain the 2 mm (0.078 in). 7. With downward pressure to the center of the hood, tighten the latch bolts. Refer to illustration above. Tighten Tighten the latch bolts to 10 N.m (89 lb in). Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal and Housing Replacement - Tools Required J 36660-A Torque Angle Meter - J 44219 Cover Alignment Pins - J 44227 Rear Seal Installer Removal Procedure 1. Remove the transmission. 2. Remove the fly wheel bolts and remove the fly wheel. 3. Remove the crankshaft rear oil seal housing bolts. 4. Install two bolts into the jackscrew holes (1) to release the cover from the block. 5. Remove the crankshaft and rear oil seal housing. 6. Remove the oil seal from the crankshaft snout. Installation Procedure Page 11438 Quarterglass Switch - R Page 2368 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 1788 Outside Moisture Sensor Page 4627 Steps 9-14 Page 4398 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Procedures Door Lock Cylinder: Procedures LOCK CYLINDER REPLACEMENT - DOOR REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector from the door. 3. Remove the outside handle from the door. 4. Remove the lock cylinder from the door handle. INSTALLATION PROCEDURE 1. Install the lock cylinder to the door handle. 2. Install the outside handle to the door. 3. Install the water deflector to the door. 4. Install the door trim panel to the door. Page 776 Involved are certain 2004 Buick Rainier, 2003-2004 Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts Pre-ship Information - For US Only Important: An initial supply of flashers required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of July 18, 2005, and will be approximately 10% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Page 2625 13. Remove the camshaft cover. 14. Clean and inspect the camshaft cover. Installation Procedure 1. Install a new camshaft cover seal. 2. install new rubber ignition control module seals. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 3. Install the camshaft cover arid secure with the cam cover bolts. Tighten the camshaft cover bolts to 10 Nm (89 inch lbs.). 4. Install the ignition control modules and secure the modules with bolts. Tighten the ignition coil bolts to 10 Nm (89 inch lbs.). Page 11412 Trunk / Liftgate Lock Cylinder: Removal and Replacement Lock Cylinder Replacement - Lift Gate Removal Procedure 1. Remove the liftgate trim panel. 2. Remove the lock rod from the lock cylinder. 3. Remove the C clip from the groove in the lock cylinder. 4. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the C clip to the groove in the lock cylinder. 3. Install the lock rod to the lock cylinder. 4. Install the trim panel. Page 1008 47. Connect the electrical connector to the A/C low pressure switch. 48. Install the lower air cleaner housing/washer solvent tank assembly onto the mounting studs. 49. Install the two air cleaner housing/washer tank assembly retaining nuts to the mounting studs. 50. Connect the washer pump hoses. 51. Connect the washer solvent tank electrical and install wiring harness to the retaining clips. 52. Install the air inlet duct to the lower air cleaner housing/washer solvent tank assembly. 53. Install the air cleaner filter element and air outlet duct. 54. Install the air cleaner cover. 55. Install the tender rear upper brace. 56. Connect the negative battery cable. 57. Recharge the refrigerant system. 58. Fill the cooling system. 59. Inspect the cooling system for leaks. 60. Leak test the refrigerant fittings using J 39400-A. Parts Information Warranty Information A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate PROM - Programmable Read Only Memory: Customer Interest A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Page 2989 6. Install the engine oil drain plug. ^ Tighten the engine oil drain plug bolt to 26 Nm (19 ft. lbs.). 7. Lower the vehicle. 8. Fill the crankcase with the proper quantity of engine oil. Page 3398 Water Pump: Description and Operation Water Pump The water pump is a centrifugal vane impeller type pump. The pump consists of a housing with coolant inlet and outlet passages and an impeller. The impeller is mounted on the pump shaft and consists of a series of flat or curved blades or vanes on a flat plate. When the impeller rotates, the coolant between the vanes is thrown outward by centrifugal force. The impeller shaft is supported by one or more sealed bearings. The sealed bearings never need to be lubricated. Grease cannot leak out, dirt and water cannot get in as long as the seal is not damaged or worn. The purpose of the water pump is to circulate coolant throughout the cooling system. The water pump is driven by the crankshaft via the drive belt. Page 3591 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. - Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. Removal Procedure 1. Loosen the PCM harness connector bolts (1) from the center of the PCM harness connectors. 2. Remove the PCM harness connectors (3) from the PCM (2). NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 3. Remove the PCM mounting nuts and bolts (4). 4. Remove the PCM (2) from the intake manifold. NOTE: Refer to PCM and ESD Notice in Service Precautions. 5. Remove the PCM mounting studs from the intake manifold, if necessary. Installation Procedure Page 13085 Power Steering Pulley Replacement Power Steering Pump: Service and Repair Power Steering Pulley Replacement Power Steering Pulley Replacement Tools Required ^ J25033-C Power Steering Pump Pulley Installer ^ J25034-C Power Steering Pump Pulley Remover Removal Procedure 1. Remove the upper radiator air intake baffle. 2. Remove the drive belt. 3. Remove the power steering pump pulley using J25034-C. Installation Procedure 1. Install the power steering pump pulley to the end of the power steering pump shaft. 2. Install the power steering pump pulley to the power steering pump using J25033-C. Page 9832 Abbreviations And Meanings Part 24 Page 6665 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 444 Specifications Wheel Bearing: Specifications Wheel Hub and Bearing Mounting Bolts 77 ft. lbs. Page 13496 area. Important: ^ Use a clean low lint towel or towelette and wipe the glass, only removing the excess adhesive promoter from the lift gate glass. ^ Do not wipe the glass dry. ^ Allow the liftgate glass to air dry completely. ^ The applique must be installed within 30 minutes following the use of the promoter. 16. Allow the adhesive promoter to remain on the glass surface for a minimum of 10 seconds. 17. Attach the CHMSL wire to the connector and install the grommet. 18. Slide the liftgate glass on the hinge pins to the left in order to allow clearance for the locating hooks. 19. Remove the protective liner from the tape on the applique. 20. Attach the locating hooks on the applique to the hinge pins. 21. Apply the applique to the liftgate glass. 22. With the heel of your hand, and starting from center of the applique and working outward towards each outer edge, apply even and consistent pressure ensuring complete contact of the adhesive strip to the glass. 23. Install the screws that retain the applique to the liftgate glass. Tighten Tighten the screws to 5 N.m (44 lb in). Important: The vehicle must be kept dry and at 21°C (70°F) to 43°C (110°F) for no less than 4 hours to ensure proper adhesive cure time. 24. Clean the liftgate glass and applique area. Parts Information Parts are currently available from GMSPO. Warranty Information Page 10160 Page 12729 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers (2) to the front door sealing weatherstrip located at the base of the pillar. 4. Close the door. Page 5781 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Page 452 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor (VSS) Page 5839 Seals and Gaskets: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement Rear Axle Shaft Seal and/or Bearing Replacement Tools Required ^ J8092 Universal Driver Handle- 3/4 inch - 10 ^ J21128 Axle Pinion Oil Seal Installer ^ J23690 Bearing Installer ^ J2619-01 Slide Hammer ^ J44685 Rear Axle Seal and Bearing Remover Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover and the gasket. 4. Remove the axle shaft. 5. Remove the axle shaft seal and/or the bearing from the axle housing using the J44685 (1) and the J2619-01 (2). Installation Procedure 1. Install the axle shaft bearing using the J23690 (1) and the J8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Page 8812 3. Disconnect the electrical connector (3) from the air temperature sensor-lower right (2). 4. Remove the air temperature sensor-lower right (2). INSTALLATION PROCEDURE 1. Install the air temperature sensor-lower right (2). 2. Connect the electrical connector (3) to the air temperature sensor-lower right (2). 3. Install the IP lower closeout panel. 4. Install the passenger side closeout panel. Upper Left AIR TEMPERATURE SENSOR REPLACEMENT - UPPER LEFT REMOVAL PROCEDURE 1. Remove the radio. 2. Remove the HVAC control module. Page 319 Page 12756 1. Install the sealing strip to the pinch-weld flange, starting at the rear edge of the door. 2. Ensure that the sealing strip is fully seated to the pinch-weld flange. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the sealing strip to the door. Tighten the screw to 1.2 N.m (10 lb in). Page 2082 Fluid - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Page 13263 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 200 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 12367 Memory Seat Module - Passenger C4 Part 3 Page 12164 Abbreviations And Meanings Part 9 Page 9988 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 4097 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 7088 C118 Page 4717 Tighten the clamps to 2.5 N.m (22 lb in). 17. Lower the vehicle. 18. Install the fuel fill pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the fuel fill pipe housing. 20. Install the fuel fill cap. Parts Information Parts are expected to be available from GMSPO on August 13, 2004. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 9506 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 787 Application Table Part 2 Page 3454 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Service and Repair Liftgate Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Window Removal Procedure 1. Open the liftgate window. 2. Pull the liftgate window weatherstrip from the liftgate window opening pinch-weld flange. Installation Procedure 1. Install the liftgate window weatherstrip, starting at the top center of the liftgate window opening position the liftgate window weatherstrip to the pinch-weld flange and working down the right and left sides towards the bottom center, being careful not to stretch the liftgate window weatherstrip while installing it. 2. Install the butt joint seam at the center of the bottom pinch-weld flange. 3. Use a rubber mallet to ensure full engagement of the liftgate window weatherstrip to the pinch-weld flange. 4. Spooning of the liftgate window weatherstrip may be required to complete the installation of the liftgate window weatherstrip. 5. Close the liftgate window. Page 9198 Registered And Non-Registered Trademarks Part 5 Page 3164 40.5. Route the other end of the harness along the rear of the engine compartment to the left side and secure to the cross bar and dash panel with tie straps. Page 13554 this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT RECALL CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the Claim Form provided to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. All recall reimbursement questions should be directed to the following number: 1-800-204-0261. Disclaimer Service Procedure Page 4431 1. Install the MAP sensor (2). 2. Install the MAP sensor retainer (1). 3. Connect the electrical connector. Page 2556 3. Align the shoe of the cylinder bore sleeve puller EN 45680-402 to the bottom of the cylinder bore sleeve (117). 4. Hold the threaded shaft of the cylinder bore sleeve puller EN 45680-402 upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve. 5. Install the fixture EN 456850-401(4) onto the threaded shaft of the cylinder bore sleeve puller EN 456850-402 and the engine block. 6. Install the bearing (3) and the nut (1). 7. Tighten the nut (1) to the bearing (3). Important: Use four old cylinder head bolts for the attaching bolts. 8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten Tighten the bolts to 15 Nm (11 lb ft). 9. Rotate the nut clockwise in order to remove the cylinder bore sleeve. 10. Remove fixture EN 45680-401, cylinder bore sleeve puller EN 45680-402, and the cylinder bore sleeve (117) from the engine block. 11. Loosen the nut (1) in order to remove the cylinder bore sleeve (117). 12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block. Page 10626 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Service and Repair Dome Lamp Bulb: Service and Repair DOME AND READING LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Carefully grasp the sides of the lens to partially expose the rear retaining tab. 2. Use a flat bladed tool in order to release the rear lens retaining tab. 3. Lower the rear edge of the lens away from the headliner. 4. Move the lens rearward in order to release the front horizontal retaining tab. 5. Remove the lens from the headliner. 6. If replacing the reading lamp bulb (1), remove the reflector (2) from the dome lamp. 7. Remove the reading lamp bulb from the socket. Page 8224 Mode Actuator Page 951 Powertrain Control Module (PCM) C2 Part 6 Page 1105 Power Mirror Switch: Service and Repair POWER MIRROR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Carefully use a flat-bladed tool in order to release the outside mirror switch retaining tabs from the trim panel. 2. Remove the outside mirror switch from the trim panel. 3. Disconnect the electrical connector from the power folding mirror switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power folding mirror switch. 2. Position the power folding mirror switch to the door trim panel. 3. Apply downward pressure to the power folding mirror switch, ensuring the retaining tabs are fully seated. Page 1739 Abbreviations And Meanings Part 3 Page 7729 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12601 Switch Replacement - Door Lock and Side Window - Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. 4. If replacing the passenger door module, program the passenger door module. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. IMPORTANT: When replacing the passenger door module, the set up procedure must be performed. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 4232 Page 6534 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 10899 Body Control Module (BCM) C1 Part 2 Page 12038 WA900J/59 - WA9260/74 Page 12237 Memory Seat Module - Passenger C4 Part 2 Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Page 7274 Abbreviations And Meanings Part 10 Page 10681 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 4171 Steps 14-16 Page 12432 Seat Cover: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 4252 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 8805 Ambient Air Temperature Sensor Page 2272 9. Install the 3 bolts (1) that retain the junction block to the block base. Tighten Tighten the 3 bolts to 3.5 N.m (31 lb in). 10. Install the BCM to the rear electrical center. 11. Install the battery feed terminal nut (2) to the junction block. Tighten Tighten the battery feed terminal nut to 10 N.m (88 lb in). 12. Install the rear electrical center cover. 13. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a passenger position. 14. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 15. Connect the battery negative cable. Page 13894 Page 9668 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Communication Interface Module Replacement 1 Global Positioning System Module: Service and Repair Communication Interface Module Replacement 1 COMMUNICATION INTERFACE MODULE REPLACEMENT (TRAILBLAZER, ENVOY, BRAVADA) REMOVAL PROCEDURE 1. Position the right rear seat bottom to a cargo position. IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification and the 11-digit electronic serial number, are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 2. Remove the protective cover from the vehicle communication interface module (VCIM). 3. Remove the module from the upper bracket by releasing the retaining tab. Page 9623 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Locations Engine Page 125 Page 3986 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. 2. Disconnect the negative battery terminal. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the Page 844 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 8176 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 2920 Conversion - English/Metric Part 2 Page 2215 Fuse Block - Rear C1 Part 5 Page 10429 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 10839 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Locations Electronic Components Page 2109 8. Install the oil level indicator. 9. Remove the oil level indicator and check the oil level. Add oil if necessary. Check for any oil leaks. Page 4220 Page 7272 Abbreviations And Meanings Part 8 Page 7904 Air Line: Service and Repair Air Suspension Air Line Replacement Removal Procedure Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensors to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: Depressurize the air suspension system only after the rear axle is supported and is set between D - Height and Full Jounce. 3. Ensure that the air suspension system is Repressurized before removing the air suspension air lines. 4. Disconnect the air line from the air spring. 5. Disconnect the air line from the air compressor. 6. Trim off air line at the electrical harness with a sharp cutting tool. Leave remaining air line in the wiring harness. Installation Procedure 1. Install air line to the air compressor using a new fitting. 2. Install air line to air spring. 3. Attach the air line to outside of the wiring harness using wire ties. 4. Lower vehicle. 5. Install air suspension system fuse. 6. Start vehicle and check for leaks. Page 13264 Abbreviations And Meanings Part 2 Page 609 Abbreviations And Meanings Part 21 Page 12930 Abbreviations And Meanings Part 19 Page 2788 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 10841 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: All Technical Service Bulletins Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 9371 Abbreviations And Meanings Part 5 A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 123 Page 12831 Abbreviations And Meanings Part 8 Page 11138 Page 4653 Steps 1-3 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Locations Automatic Transmission Page 2205 Application Table Part 3 Page 12622 Power Seat Switch: Diagrams Lumbar Adjuster Switch - Driver (w/o Memory) Page 2946 Abbreviations And Meanings Part 18 Page 3501 Abbreviations And Meanings Part 18 Page 12124 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 9770 Page 9854 Page 4931 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 7286 Abbreviations And Meanings Part 22 Page 9633 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 9634 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 3246 Do NOT replace an EV fan unless a specific condition related to the EV fan is identified using SI diagnostics. If the fan has a condition that warrants replacement, a DTC should set and/or SI diagnostics should lead to the replacement of the fan clutch. If the fan is not operating at the proper speed/function, the appropriate diagnostic trouble code should set. Identify the root cause of the condition. Please make sure to do a thorough review of SI for proper diagnostics. Several Service Bulletins and Preliminary Information are available on SI regarding the EV fan. Refer to "Operating Characteristics" and "Diagnostic Tips" in this bulletin for additional information. Operating Characteristics of the Electro-Viscous (EV) Fan Clutch Changes to the EV fan clutch to improve the HVAC performance basically increase airflow in certain conditions. It is now possible during start up for the EV fan clutch to be engaged and match engine speed for about 1 minute depending on driving speeds (with lower speeds having a longer disengagement time) producing some noise/flare. The noise/flare will most likely be intermittent and can be dependent on the following conditions: ^ Fan clutch valve orientation, with check ball at 11:00 position as viewed from front of vehicle when the engine is stopped. ^ HVAC or powertrain cooling conditions when the vehicle is shut off. ^ Parking incline - vehicles parked nose up on a 16% or higher incline (such as vehicles coming off transport or parked on steep driveways) may have prolonged fan noise/flare until the fluid is pumped out of the working chamber of the fan. These conditions can occur in as little as ten minutes. Once the vehicle is not parked in these conditions, it should operate as expected. ^ Please note that if the vehicle is parked nose down with a 16% or more decline, the EV fan clutch may have a delayed engagement response similar to what is described in Corporate Bulletin Number 04-01-38-019A. Important: Do not replace EV fan clutches for these conditions listed above; they are expected vehicle characteristics. If the fan clutch is truly operating at a speed higher than intended, a DTC P0495 or P1484 should set. Additional codes are available for other conditions. Diagnostic Tips Depending on the vehicle year, the Tech 2(R) may allow some EV fan control using the special functions application of the Tech 2 (refer to the proper SI documentation). If this function or a fused jumper wire is being used to check EV fan response, there may be a delay in fan response (up to 2-3 minutes depending on conditions, please refer to SI diagnostics). The desired fan speed and actual fan speed data (on the Tech 2(R)) can be misleading. The desired fan speed is comprised of the maximum of multiple parameters (for example engine coolant temp, A/C pressure, etc.) and may not be the ruling desired fan speed parameter. The end result may be that the actual desired fan speed is lower than what is displayed. Additionally, the desired fan speed may be higher than the current engine speed. The fan is limited by the current engine RPM and will max out at about 3500 RPM under full manual fan engagement request along with a corresponding engine RPM speed. The 4.2L 1-6 (LL8) engine's desired and actual fan speeds will usually be closer to each other than the 5.3L V-8 (LM4 or LH6) or the 6.0L V-8 (LS2). Disclaimer Page 818 Page 5671 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Application and ID Relay Box: Application and ID Location View Application Table Part 1 Page 12425 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Rear No. 2 SEAT BACK FRAME REPLACEMENT - REAR NO. 2 REMOVAL PROCEDURE 1. Remove the head restraint assembly. 2. Remove the seat back cover and pad. 3. Remove the two bolts (1) securing the outer riser assembly to the seat back frame. 4. Remove the two bolts securing the inner riser assembly to the seat back frame. 5. Remove the seat back. INSTALLATION PROCEDURE 1. Install the two bolts securing the inner riser assembly to the seat back frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat back mounting bolts to 25 N.m (18 lb ft). 2. Install the seat back cover and pad. 3. Install the head restraint assembly. Page 4304 Body Control Module (BCM) C1 Part 3 Automatic Control Air Door Actuator / Motor: Service and Repair Automatic Control Auxiliary AIR TEMPERATURE ACTUATOR REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the air temperature actuator. 3. Remove the retaining screws from the air temperature actuator. 4. Remove the air temperature actuator (1) from the rear HVAC module. INSTALLATION PROCEDURE 1. Install the air temperature actuator (2) to the rear HVAC module. 2. Install the screws to the actuator. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector to the air temperature actuator. 4. Recalibrate the air temperature actuator, See: Testing and Inspection/Programming and Relearning 5. Install the right rear quarter trim panel. Page 7862 Lateral Stabilizer Rod: Service and Repair Rear Axle Tie Rod Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Raise and support the rear axle at the designed D - height. Important: When disconnecting the rear axle tie rod, the air suspension system must be Repressurized or the body my shift during the repair. 3. If equipped with air suspension, Repressurize the air suspension system. 4. Remove the rear axle tie rod to the axle mounting bolt and nut. 5. Remove the rear axle tie rod to frame mounting bolt and nut. 6. Remove the rear axle tie rod from the vehicle. Installation Procedure Important: When installing the rear axle tie rod the bushings inner sleeve off set (largest gap) is towards the rear axle. Page 9099 Impact Sensor: Description and Operation INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The Side Impact Sensor (SIS) contains a sensing device (accelerometer) which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIS is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops deploying the side air bags. Page 3423 7.2. Cut the exhaust pipe (1), where the damage is located. 7.3. Remove the damaged exhaust pipe and resonator. Installation Procedure 1. If replacing the whole muffler assembly, carefully install the muffler into place on the vehicle and secure the exhaust hangars to the insulators. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the muffler to the catalytic converter pipe and secure the pipe with the nuts. Tighten the nuts to 45 Nm (33 ft. lbs.). 3. If replacing exhaust aft of the muffler: 3.1. Connect exhaust to insulators as required. 3.2. Install exhaust pipe to muffler. Tighten the clamp nuts to 50 Nm (37 ft. lbs.). 3.3. Remove the exhaust support. 4. Inspect the exhaust system for leaks and underbody contact. 5. Install the frame brace (required on extended versions). 6. Lower the vehicle. Page 4116 Abbreviations And Meanings Part 2 Page 6067 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Page 2664 Drive Belt Vibration Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure. Page 11475 outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the Page 11081 Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. Page 13259 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 4360 Powertrain Control Module (PCM) C2 Part 4 Specifications Brake Bleeding: Specifications Brake System Pressure Bleed Initial Pressure Adjustment Setting, Leak 10 psi Testing the Hydraulic Brake System. Pressure Bleed Procedure Setting 35 psi Page 9560 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 13583 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11120 7. Pass the feed wire (1) through the hinge (2), body pillar (3) and backing plate (4). 8. Crimp the feed wire (1) behind the backing plate. 9. Pull the feed wire (1) while guiding the backing plate (2) into the inner structure. 10. Place the hinge (1) into position and hand tighten the 2 attaching bolts. Specifications Vacuum Brake Booster: Specifications Power brake vacuum booster mounting nut 30 ft.lbs. Vacuum Power Assist 2.4 in Page 338 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Locations Blower Motor Switch: Locations Front Auxiliary Blower Motor Switch (w/Manual HVAC System / Body Type VIN 6) Specifications Brake Master Cylinder: Specifications Brake Master Cylinder Mounting Bolts 27 ft. lbs. Page 10172 Page 10 Page 11210 Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) Page 11047 10. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge. Installation Procedure 1. Position the service hinge (1) within the scribe marks (2) on the door (3). 2. Mark each hole location on the door according to the service hinge (4). 3. Drill a 3 mm (1/8 in) pilot hole at each location (1). 4. Drill a 13 mm (1/2 in) hole at each pilot hole location (2). 5. Clean and prepare all bare-metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-2001 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an anti-corrosion primer. Page 9121 Page 4107 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Locations Trailer Connector Page 3963 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). 7. Disconnect the 40-way body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. Page 1698 Page 5337 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. ^ Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. Locations Memory/Heated Seat Switches Page 1241 Blower Motor Switch: Diagrams Blower Motor Switch - Front Auxiliary (Body Type VIN 6) Page 6865 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 14011 Page 7080 C101 Part 3 Page 7631 3. Connect the air spring level sensor electrical connector. Notice: Failure to remove the air suspension auto level control sensor locating pin before the rear axle support is removed will cause damage to the air suspension auto level control sensor. 4. Remove the air spring level sensor locating pin. 5. Remove the rear axle support. 6. Install the rear tire and wheels. 7. Lower the vehicle. 8. Install the air suspension system fuse. 9. Start the vehicle and run for approximately 1 minute to ensure that the air spring leveling system is functioning properly. 10. Check the D height. Page 820 Page 4308 Body Control Module (BCM) C3 Part 4 OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 13970 Steps 1-3 Page 6209 Abbreviations And Meanings Part 8 Page 10539 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 13563 Involved are certain 2004 Buick Rainier, 2003-2004 Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts Pre-ship Information - For US Only Important: An initial supply of flashers required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of July 18, 2005, and will be approximately 10% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Page 8250 See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb ft). 3. Install the air inlet assembly. 4. Install the air inlet assembly screws. Tighten Tighten the screws to 1.9 N.m (17 lb ft). 5. Connect the electrical connector to the recirculation actuator. 6. Install the HVAC module assembly. Page 11170 Involved are certain 2002-2003 Chevrolet TrailBlazer EXT and GMC Envoy XL vehicles operated in corrosion areas and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts Pre-Ship Information Important: Page 12193 Mirror Connector, Driver Door Module (DDM) - C3 Part 2 Page 9009 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 4. Connect the IP module yellow 4-way connector (1) located behind the IP support. 5. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. Page 13916 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 7261 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 7303 7. Using your finger, remove the socket retaining ring by pulling the retaining ring out of the mounting hole. INSTALLATION PROCEDURE 1. Position the retaining ring to the mounting hole. 2. Index the key to the retaining ring to the slot in the mounting hole. 3. Install the retaining ring by pressing the retaining ring into the mounting hole until fully seated. 4. Connect the electrical connector to the socket. 5. Position the socket to the retaining ring. 6. Install the socket into the retaining ring by pressing in the socket until fully seated. 7. Install the 12 volt power supply or cigar lighter fuse. Locations Engine, Right Front Page 834 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 3510 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 9598 For vehicles repaired under warranty, use the table. Disclaimer Page 10866 Abbreviations And Meanings Part 2 Page 121 Page 6790 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 13310 Miniwedge (Door Jamb Switch) - LR Page 9745 DVD Player: Description and Operation DVD PLAYER The DVD player and the video display screen are located in the overhead console. The DVD player can be controlled by both the buttons on the DVD player and by the buttons on the remote control. The DVD player power may be turned on when the ignition is in the run, accessory, or Retained Accessory Power (RAP) power modes. DVD's are manufactured with different region codes based on the country in which they are sold. Therefore, the RSE system DVD player is only compatible with the region code. where the vehicle is sold. The DVD region code is printed on the jacket of most DVD's. The DVD player will also play audio CD's. Home recorded CD's (CD-R or CD-RW formats) will not play in this DVD player. Locations Oxygen Sensor: Locations Engine, Right Side Page 7124 C700 Part 2 Page 10712 7. Install the protective cover (1) to the module. 8. Position the right second row seat to a passenger position. 9. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 10. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 11. Use the ID information menu on the scan tool to access the new station ID (STID) and the electronic serial number (ESN) from the new VCIM. 12. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center and perform the following procedure: 12.1. Tell the advisor that this vehicle has received a new VCIM. 12.2. Ask the advisor to add the new STID and the ESN to update the customer's account. 12.3. Follow any additional instructions from the OnStar(R) advisor. 12.4. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Page 4070 Page 9936 Disclaimer Page 10441 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 3276 10. Unclip the fan shroud from the radiator at the side panels (1). 11. Tilt the radiator and the condenser forward. 12. Lift the fan and the shroud up and out towards the engine to release the fan from the radiator to clear the radiator inlet. Installation Procedure 1. Install the fan and the shroud onto the lip of the radiator bottom. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the 2 bolts into the upper fan shroud and tighten. Tighten the bolts to 28 Nm (21 ft. lbs.). 3. Connect the electrical connector. 4. Clip the fan shroud to the radiator at the side panels (1). Page 6289 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Page 6693 Abbreviations And Meanings Part 15 Page 9979 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 4582 Fuel: Testing and Inspection Without Special Tools TEST DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Alcohol concentrations of 10 percent or more in the fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation, lack of power, stalling, or no start. ALCOHOL IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml (3.38 oz) specified cylinder with 1 ml (0.034 oz) graduation marks, fill the cylinder with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid volume to 100 ml (3.38 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. PARTICULATE CONTAMINANTS IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter (0.53 qt) of fuel. 2. Place the container on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. 3. Observe the fuel sample. If any physical contaminants or water are present, clean the fuel system. Refer to Fuel System Cleaning. Page 891 Body Control Module (BCM) C1 Part 1 Page 12110 Page 12329 Head Rest: Removal and Replacement Head Restraint Replacement - Front Seat Head Restraint Replacement - Front Seat Removal Procedure 1. Raise the head restraint to the full up position by pressing the release tab (2), and by lifting up the head restraint. 2. Insert a small tool into the head restraint retainer port (1). 3. In order to release the head restraint retainer, simultaneously lift up on the head restraint while applying inward pressure to the tool in the retainer release port (1). 4. Remove the head restraint from the seat assembly. Installation Procedure 1. Position the head restraint to the seat assembly. 2. Verify that the notches in the head restraint posts are indexed toward the rear of the seat assembly. 3. Push the head restraint downward into the fully installed position. 4. Raise the head restraint to the full up position. Verify that the head restraint retainer prevents the head restraint from being removed from the seat assembly. Head Restraint Guide Replacement - Front Seat Head Restraint Guide Replacement - Front Seat Removal Procedure 1. Remove the front seat assembly. 2. Remove the front seat head restraint. 3. Pull the seat back cover and the seat back pad up high enough to expose the head restraint guides. Refer to Seat Back Cover and Pad Replacement - Front. 4. Squeeze the retaining tabs located at the bottom of the guides together in order to remove the guides from the seat frame. 5. Remove the guides from the seat back frame. Page 2378 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 2130 Disclaimer Page 8750 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Page 1969 Drive Belt Falls Off Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. The drive belt may have been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Page 12616 Seat Lumbar Motors And Position Sensors Assembly - Driver Part 2 Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 7424 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 7257 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 6135 1. Install sensor into the hub and bearing assembly (6). ^ Tighten the sensor mounting screw (5) to 18 Nm (13 ft. lbs.). Important: The new sensor has new mounting clips already installed on the wire. DO NOT reuse the old clips. 2. Connect the wheel speed sensor electrical connector (2). 3. Install wheel speed sensor mounting clip to the frame rail. 4. Install the wheel speed sensor mounting clip to the control arm. 5. Install the hub and rotor. 6. Install brake caliper. 7. Install tire and wheel. Page 964 Locations View Page 12541 Abbreviations And Meanings Part 9 Page 9081 5. Install the rear seat belt center retractor nut. Tighten Tighten the rear seat belt center retractor nut to 35 N.m (26 lb ft). 6. Install the seat belt into the retractor bracket by guiding the belt through the slot in the bracket. 7. Install the rear seat back pad and cover. 8. Install the rear seat back seat belt bezel onto the seat belt. 9. Install the seat belt bezel to the seat back. Page 13888 Page 780 1. Remove the 2 screws that retain the insulator panel to the instrument panel (I/P). 2. Release the insulator panel retaining clip from the I/P substrate. 3. Lower the insulator panel. 4. Remove the flasher retaining bracket from the insulator panel. 5. Disconnect the flasher from the electrical connector. 6. Remove the flasher from the vehicle. 7. Position the new flasher to the insulator panel. 8. Connect the electrical connector to the flasher. 9. Install the flasher retaining bracket to the insulator panel. 10. Install the insulator panel tabs to the cowl slots. 11. Raise the insulator panel to the I/P. 12. Install the insulator panel retaining clip to the I/P substrate. 13. Install the 2 screws that retain the insulator panel to the I/P. Tighten Tighten the screws to 2.5 N.m (22 lb in). Locations Door Lock Switch, Window Switch, Driver Door Module (DDM) Page 229 Seat Back Frame Replacement - Front Seat Back Frame: Service and Repair Seat Back Frame Replacement - Front SEAT BACK FRAME REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the seat assembly from the vehicle. 2. Remove the seat trim panel. 3. Remove the front seat back. 4. Remove the seat back cover and pad. 5. Remove the front seat back panel. 6. Remove the lumbar assembly. 7. Remove the seat belt and retractor assembly. 8. Remove 2 screws (1) securing the inflatable side impact module to the seat back frame. 9. Remove the 2 push pins (1) securing the side impact module tub to the seat back frame. Page 7106 C307 Part 3 Page 228 Page 4182 Knock Sensor (KS) 2 Front Page 6950 Fuse Block - Rear C1 Part 3 Locations Electronic Components Page 12564 Registered And Non-Registered Trademarks Part 6 Page 3540 6. Install the rear electrical center cover. 7. If replacing the body wiring harness extension on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 8. If replacing the body wiring harness extension on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 9. Connect the negative battery cable. Page 13989 1. Use a grease pencil in order to mark the grid line break (2) on the outside of the rear window with a grease pencil. IMPORTANT: Ensure that the grid line repair material is not beyond the expiration date. - Repair decal or tape must be used in order to control the width of the repair area. - If the repair decal is used, verify that the die-cut metering slot is the same width as the grid line. - Thoroughly stir the grid line repair material until a uniform color appears. - Verify that there are no air bubbles in the grid line repair material in the repair area. 1. Using GM P/N 12346001 (Canadian P/N 10951643) or equivalent to repair the grid lines. Apply the grid line repair (2) decal or 2 strips of the tape above and below the repair area. 2. Use the brush (3) in order to spread the grid line repair material (1). Ensure that the repair material covers all of the areas of the cut out. 3. Without disturbing the grid line repair material, carefully remove the decal or tape (2). NOTE: The grid line repair material must be cured with heat. To avoid heat damage to the interior trim, protect the trim near the repair area where heat is to be applied. 4. Use a heat gun in order to repair the grid line: - Hold the heat gun nozzle 25 mm (1 in) from the surface. - Heat the repair area for 2-3 minutes. IMPORTANT: Use J 25070 capable of 260°C (500°F) or equivalent. If you do not use a heat gun, allow at least 24 hours at an ambient temperature of 21-32°C (70-90°F) for complete curing of the repair materials. Do NOT physically disturb the repair area until after that time. The grid line will be electrically operative immediately after the repair. Page 12387 Position Sensor - Rear Motor (w/Memory) Page 12816 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. HVAC System - Automatic Air Door Actuator / Motor: Locations HVAC System - Automatic Instrument Panel Carrier Page 13141 Abbreviations And Meanings Part 13 Page 12446 Tighten Tighten the nuts to 25 N.m (18 lb ft). 16. Install the 3 seat switch bezel screws. Seat Cushion Trim Panel Replacement - Rear No.1 SEAT CUSHION TRIM PANEL REPLACEMENT - REAR NO.1 (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the rear seat bracket trim covers (1). 3. Remove the rear seat bracket mounting nuts (2). 4. Remove the rear seat bracket. 5. Remove the two bolts (2) securing the support (1) to the seat cushion trim panel. Page 2075 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Page 1789 Rain Sensor: Service and Repair WINDSHIELD OUTSIDE MOISTURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the rain sensor (1). IMPORTANT: The rain sensor retaining ring is permanently mounted to the windshield and is not serviceable. Damage to the windshield or the retaining ring will occur if removed. 2. Carefully pull downward on sensor (1) to release it from the retaining ring (2). 3. Remove the sensor from the vehicle. IMPORTANT: Do not touch the surface of the sensor when it is removed from the glass. INSTALLATION PROCEDURE 1. Clean the mounting location on the windshield using a clean lint free cloth with isopropyl alcohol. 2. Install the rain sensor (1) to the windshield. 3. Connect the electrical connector to the rain sensor (1). Page 50 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 127 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Diagrams Volume/AM/FM Switch (With RPO Code STW) Page 6002 Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side Page 4111 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 6780 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 5314 For vehicles repaired under warranty, use the table. Important: ^ This labor time ONLY applies to vehicles repaired WITHOUT the transmission removed from the vehicle. ^ NO additional labor time is required for installation of the fill tube while the transmission is removed from the vehicle for repair. Disclaimer Page 2420 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 1503 16. Remove the nut and bolt securing the coolant recovery reservoir. 17. Remove the coolant recovery reservoir with the accumulator attached. 18. Remove the evaporator tube nut at the evaporator. 19. Remove the evaporator tube from the evaporator 20. Using the J 43181, disconnect the heater hoses from the core. 20.1. Install the J 43181 to the heater core hose. 20.2. Close the tool around the heater core hose. 20.3. Firmly pull the tool into the quick connect end of the heater hose. 20.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 21. Disconnect the coolant bypass valve hose from the auxiliary rear heater line. 22. Disconnect the coolant bypass valve hose from the engine. 23. Disconnect the electrical connector from the coolant bypass valve. This connector will no longer be used. Tape off with electrical tape. 24. Disconnect the vacuum hose from the coolant bypass valve. 25. Remove the nut retaining the coolant bypass valve to the cowl and remove the coolant bypass valve with hoses attached. 26. Remove the heater hose quick connect retainers from the heater core pipes. 27. Remove the four nuts and the HVAC plate from the dash panel. 28. Attach the new auxiliary heater pump to the new bracket using the supplied retainers as shown. Note the position of the pump on the bracket. Page 13637 1. Install the horn switch (2) to the steering wheel (3). Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the horn contact plate (2) captured screws (1, 4) to the steering wheel (3). Tighten the screws to 5.5 Nm (50 inch lbs.). 3. Install the horn plunger to the steering column. 4. Install the inflator module. 5. Enable the SIR system. Page 6447 - Symptoms - Drive Belt Drive Belt: Testing and Inspection - Symptoms - Drive Belt Drive Belt Chirping See: Drive Belt Chirping Drive Belt Squeal See: Drive Belt Squeal Drive Belt Whine See: Drive Belt Whine Drive Belt Rumbling See: Drive Belt Rumbling Drive Belt Vibration See: Drive Belt Vibration Drive Belt Falls Off See: Drive Belt Falls Off Drive Belt Excessive Wear See: Drive Belt Excessive Wear Drive Belt Tensioner See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Testing and Inspection Page 8343 Page 6347 Brake Caliper: Service and Repair Brake Caliper Overhaul Front Brake Caliper Overhaul- Front ^ Tools Required J 8092 Driver Handle - J 43885 Boot Seal Installer Disassembly Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions 1. Drain all the brake fluid from the caliper. 2. Pad the interior of the caliper with clean shop towels. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding. 3. Remove the pistons (2) from the caliper bores. 4. Remove the boots (1) from the caliper bores. Do not scratch the caliper bores. 5. Remove the piston seals (3) from the caliper bores. Do not use a metal tool. 6. Remove the bleeder valve cap (4). 7. Remove the bleeder valve (5) from the caliper housing (6). 8. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 9. Replace the pistons or the caliper if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston Chrome plating damage on the piston ^ Corrosion in the caliper bore Use a crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore Assembly Procedure Page 5711 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Page 3944 Registered And Non-Registered Trademarks Part 5 Page 12543 Abbreviations And Meanings Part 11 Page 8929 Clockspring Assembly / Spiral Cable: Service and Repair INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR System. Refer to SIR Disabling and Enabling Zone 3. CAUTION: Refer to SIR Caution in Service Precautions. 2. Remove the inflatable restraint steering wheel module. 3. Remove the steering wheel nut. 4. Note the mark on the steering shaft and the steering wheel to ensure proper alignment during installation. 5. Remove the steering wheel from the steering shaft. 6. On vehicles with a tilt column, pull the tilt lever straight out from the steering column. 7. Remove the tilt lever assembly. 8. Remove 2 TORX(R) head screws (1) from the lower shroud (2). 9. Remove the lower shroud (2). Diagram Information and Instructions Auxiliary Blower Motor: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 9355 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 1548 Impact Sensor: Description and Operation INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The Side Impact Sensor (SIS) contains a sensing device (accelerometer) which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIS is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops deploying the side air bags. Page 6759 Page 10132 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 10926 2. Position the assist step assembly to the vehicle. 3. Install the bolts that retain the support brackets to the body. Tighten the bolts to 25 N.m (18 lb ft). Page 9503 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 2269 8. Release the tabs that retain the junction block to the block base. 9. Remove the junction block from the block base. 10. Disconnect the instrument panel harness connector (1) from the junction block. 11. Disconnect the mobile telephone harness connector (1) from the junction block. Locations Instrument Panel Page 7838 7. Pivot the lower control arm outward and downward for access to the lower control arm bracket. 8. Remove the lower control arm bracket mounting bolts from the frame. 9. Remove the lower control arm bracket from the vehicle. Installation Procedure 1. Install the lower control arm bracket to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower control arm bracket mounting bolts to the frame. ^ Tighten the front lower control arm bracket mounting bolt to 260 Nm (192 ft. lbs.). ^ Tighten the rear lower control arm bracket mounting bolts to 240 Nm (177 ft. lbs.). 3. Install the lower control arm to the lower control arm bracket. 4. Install the lower control arm to lower control arm bracket mounting bolts. Page 2871 9. Remove the generator. 10. Loosen and remove the intake manifold bolts. 11. Remove the intake manifold. Installation Procedure 1. Install a new intake manifold gasket. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the intake manifold onto the engine and secure the manifold with the bolts. Tighten the intake manifold bolts to 10 Nm (89 inch lbs.). 3. Install the generator. 4. Install the brake hose to the booster. 5. Lubricate the inner diameter of the crankcase ventilation hose with GM P/N 12345884 (Canadian P/N 5728223) or equivalent. Page 11661 45. If the vehicle is equipped with a sunroof, partially lower the headliner and disconnect the sunroof assembly electrical connector. 46. With the aid of an assistant, remove the headliner from the vehicle. Installation Procedure 1. With the aid of an assistant, install the headliner into the vehicle. 2. If the vehicle is equipped with a sunroof, partially raise the headliner and connect the sunroof assembly electrical connector. 3. With the aid of an assistant, fully raise the headliner and ensure that the retaining strips (1) are engaged, and the headliner harnesses (4) hang free of the headliner. 4. Install the assist handles to the roof panel. 5. Install the right rear push pin (2). 6. Install the left rear push pin (3). 7. Install the 3 push pins in the center of the headliner. 8. Install the sunshades to the headliner. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the left and right sunshade retaining clips (5). Tighten the sunshade retaining clip screws to 10 N.m (88 lb in). Page 451 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 5729 Valve Body Spring and Bore Plug Chart (inch) Page 1905 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Locations Engine, Right Front Page 9777 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 7475 C301 Part 2 A/T - Water Or Coolant Contamination Information Transmission Cooler: All Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Electrical - Intermittent Interior Electrical Concerns Turn Signal Flasher: Customer Interest Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 7262 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 679 Endgate Module (EGM) C2 (XUV) Part 1 Page 10366 Abbreviations And Meanings Part 19 Page 7485 C307 Part 3 Page 13447 Brake Lamp: Description and Operation STOP LAMPS The STOP fuse in the engine wiring harness junction block supplies battery positive voltage to the normally open stop lamp switch. When the driver presses the brake pedal, the switch contacts close and battery positive voltage is supplied to both the VEHICLE STOP fuse and the VEHICLE CHMSL fuse. The current flow is now to the stop lamps which are grounded at G401 and G402. The center high mounted stop lamp (CHMSL) is grounded at G401. For trailer wiring, a separate stop lamp circuit is connected through the GMSF to the trailer wiring harness. Page 777 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition contained in this bulletin are to be submitted by August 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle Page 12041 WA9539/47 - WA9539/47 Page 13231 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 9147 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: Customer Interest Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 5649 Transmission Cooler: Service and Repair Transmission Oil Cooler Line Quick Connect Fitting Removal Procedure Important: The front and rear sections of the cooler lines can be serviced separately. Refer to the appropriate steps when servicing individual lines. Perform the following procedure when removing the cooler lines from the quick connect fittings. 1. Pull the plastic cap back from the quick connect fining and down along the cooler line about 5 cm (2 inch). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fining until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Important: ^ Do not reuse any of existing fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. All retaining rings being installed must be new. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. Page 11497 3. Install the bellcrank rod to the outside door release handle. 4. Install the liftgate trim panel. 5. Install the license pocket lamps. Page 6953 Fuse Block - Rear C1 Part 6 Fuse Block - Rear C2 Fuse Block - Rear C2 Part 1 Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 9050 Seat Belt Buckle: Service and Repair Buckle Replacement - Center Rear (TrailBlazer EXT, Envoy XL) REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the trim panel from the seat cushion. 3. Remove the bolt (1) securing the center buckles to the mid-position floor latch assembly. 4. Remove the center seat belt buckles. INSTALLATION PROCEDURE 1. Install the center seat belt buckles to the mid-position floor latch assembly with the bolt (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear center seat belt buckle assembly bolt to 60 N.m (44 lb ft). 2. Install the trim panel to the seat cushion. 3. Install the seat in the vehicle. Page 3729 For vehicles repaired under warranty, use the table. Disclaimer Page 10344 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Body - Rear License Plate Pocket Gasket is Loose License Plate Bracket: All Technical Service Bulletins Body - Rear License Plate Pocket Gasket is Loose Bulletin No.: 04-08-66-001E Date: December 13, 2007 TECHNICAL Subject: Rear License Plate Pocket Perimeter Gasket Loose/Out of Position Or Excessive Amount Of Adhesive (Install New Gasket Using Updated Retainer Tightening Sequence) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2008 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and change the part numbers. Please discard Corporate Bulletin Number 04-08-66-001D (Section 08 - Body & Accessories). Condition Some customers may comment that the insulating perimeter seal or gasket on the backside edge of the license plate housing/pocket appears to be shrinking or becomes pulled away from the edge of the license plate housing/pocket. Some customers may also comment about excessive amounts of adhesive oozing from the gasket. Cause This condition may be caused by changes in temperature, which may cause the plastic license plate housing to expand and contract. When this occurs, the license plate housing gasket seal may be caught and pulled under the housing/pocket. Correction A new gasket without the adhesive has been released for service. Technicians are to replace the rear license plate pocket perimeter gasket using the following procedure: Excessive amounts of adhesive, which may have oozed from the gasket, may be cleaned using GM Tar and Road Oil Remover, P/N 1050172 (in Canada, P/N 992856), or the equivalent. Remove the rear license plate pocket assembly. Refer to the License Plate Pocket Replacement procedure in the Body Rear End (2006 MY and prior) or Exterior Trim sub-section of SI. Remove the rear license plate pocket perimeter gasket. Page 1009 For vehicles repaired under warranty, use the table. Disclaimer Page 14015 Rear Defogger: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 12420 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Rear No. 1 - 1 SEAT BACK FRAME REPLACEMENT - REAR NO. 1 (TRAILBLAZER, ENVOY, BRAVADA) REMOVAL PROCEDURE 1. Remove the seat back cover and pad. 2. Remove the latch release assembly. 3. Remove the head restraint retractor assembly. 4. Remove the seat back hinge brackets. 5. Remove the seat belt retractor assembly, on the left side only. 6. Remove the latch release cable (1), and the head rest restraint cable (2) from the left-hand hinge bracket. 7. Remove the latch release cables from the right-hand hinge bracket. INSTALLATION PROCEDURE Page 4592 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the fuel pressure service connection cap. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Install the fuel tank shield if removed. Page 4678 Page 3453 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Locations Park Neutral Position (PNP) Switch Page 12258 Sunroof Module C2 LF Page 5928 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Slde Page 8659 11. Disconnect the electrical connectors from the HVAC module. 12. Disconnect the rear compartment air outlet ducts (5) from the HVAC module (3). 13. Remove the mounting bolts (5) from the HVAC module. 14. Remove the HVAC module (1). 15. Remove and discard the HVAC module pass through seal. INSTALLATION PROCEDURE 1. Install new HVAC module pass through seal. 2. Install the HVAC module (1). OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 13854 Vanity Mirror Lamp - RF Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: Customer Interest Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 9166 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 5749 Notice: Refer to Fastener Notice in Service Precautions. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the control valve body bolts (in sequence) to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the manual detent spring bolt to 31 Nm (23 ft. lbs.). 12. Install the TCC solenoid with a new O-ring seal to the valve body. Page 2768 Page 3359 Radiator Hose: Service and Repair Outlet Body VIN Code 3 Radiator Hose Replacement - Outlet (Body Vin Code 3 / GMT 360) Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the engine coolant. 2. Reposition the inlet radiator hose clamp (2) at the radiator using J 38185. 3. Remove the inlet radiator hose from the radiator. 4. Reposition the inlet radiator hose clamp (1) at the engine outlet using J 38185. 5. Remove the inlet radiator hose from the engine. Installation Procedure 1. Install the inlet radiator hose clamps (1, 2) to the radiator hose. 2. Install the inlet radiator hose to the engine. 3. Reposition the inlet radiator hose clamp (1) using J 38185. 4. Install the inlet radiator hose to the radiator. 5. Reposition the inlet radiator hose clamp (2) using J 38185. 6. Fill the cooling system. Body VIN Code 6 Radiator Hose Replacement - Outlet (Body Vin Code 6 LL8 / GMT 370) Tools Required J 38185 Hose Clamp Pliers Page 6916 Registered And Non-Registered Trademarks Part 5 Page 5745 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. 12. Reposition the harness to the side of the transmission case. 13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. Page 9812 Abbreviations And Meanings Part 4 Page 9002 6. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 7. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 8. Disconnect the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 9. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 10. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Page 10281 Speaker - RF Door Page 2818 Abbreviations And Meanings Part 16 Page 640 3. Install the screw that retains the seat control module to the seat pan. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat module screw to 3 N.m (26 lb in). 4. Install the seat pan to the seat assembly. 5. Install the nuts which retain the seat pan to the seat assembly. Tighten Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 6. Install the 3 seat switch bezel screws. Page 6027 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install TCC PWM solenoid retainer. Page 12176 Abbreviations And Meanings Part 21 Page 8374 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Service and Repair Front Door Window Regulator: Service and Repair Window Regulator Replacement - Front Door Removal Procedure 1. Remove the door trim panel. 2. Remove the speaker. 3. Remove the water deflector. 4. Loosen the regulator window carrier bolts. 5. Raise and support the window. 6. Disconnect the electrical connector from the regulator motor. 7. Loosen the upper 2 bolts that retain the regulator assembly to the door. 8. Remove the remaining 3 bolts that retain the window regulator assembly and the motor to the door. 9. Lift the regulator assembly upward in order to release the upper 2 bolts. 10. Rotate the upper portion of the regulator assembly forward. 11. Beginning with the lower portion, remove the regulator assembly through the door opening. 12. Place the regulator assembly on a prepared surface. 13. Remove the upper 2 bolts from the regulator assembly. Installation Procedure 1. Partially install the upper 2 bolts to the regulator assembly. 2. Beginning with the upper portion, install the regulator assembly through the door opening in a semi-horizontal position. 3. Position the regulator assembly fully forward into the door cavity. 4. Rotate the regulator assembly to a vertical position. 5. Lower and hang the regulator assembly onto the door sheet metal using the upper 2 bolts that were previously installed. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolt that retains the motor to the door. Tighten bolts to 9 N.m (80 lb in). 7. Install the remaining bolts that retain the regulator assembly to the door. Tighten bolts to 10 N.m (88 lb in). 8. Connect the electrical connector to the regulator motor. 9. Remove the window support and lower the window onto the regulator window carrier. 10. Loosely tighten the regulator window carrier bolts. 11. Operate the window upward to the full up position, ensuring the window remains in the run channels. Tighten the regulator window carrier bolts to 10 N.m (88 lb in). Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 1193 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. 2. Disconnect the negative battery terminal. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the Page 12938 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 12142 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 12198 Front Passenger Door Module (FPDM) - C2 Part 2 Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Only if necessary remove the fuel tank shield. IMPORTANT: Due to an access hole in the fuel tank shield, removal of the shield should not be necessary to access the fuel pressure service connection. 3. Remove the fuel pressure service connection cap, located near the fuel filter. 4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Turn ON the ignition. 6. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 8. Command the fuel pump ON with a scan tool. 9. Close the bleed valve on the fuel pressure gage. 10. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. Page 12453 4. Remove the 3 bolts securing the rear seat cushion latch to the seat pan. INSTALLATION PROCEDURE 1. Install the 3 bolts securing the rear seat cushion latch to the seat pan. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat cushion latch release bolts to 10 N.m (88 lb in). Page 13950 Abbreviations And Meanings Part 20 Page 6902 Abbreviations And Meanings Part 17 Campaign - Fuel Tank Reservoir Corrosion Warranty Ext. Technical Service Bulletin # 07076A Date: 081105 Campaign - Fuel Tank Reservoir Corrosion Warranty Ext. SPECIAL COVERAGE Bulletin No.: 07076A Date: November 05, 2008 Subject: 07076A - SPECIAL COVERAGE ADJUSTMENT - FUEL TANK MODULAR RESERVOIR ASSEMBLY CORROSION Models Supercede: The ending breakpoints for the 2002 Chevrolet TrailBlazer and the 2003 Chevrolet TrailBlazer EXT have been revised. Please discard all copies of bulletin 07076, issued September 2008. Condition Page 8413 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 680 Endgate Module (EGM) C2 (XUV) Part 2 Page 2756 Page 13097 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 13262 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 10409 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 13719 Door Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the rear door ajar switches in the door lock assemblies as one method to activate the alarm. The body control module (BCM) monitors rear door ajar switches via a discrete input from each rear passenger door ajar switch, if the BCM receives a ground signal from a rear passenger door ajar switch when the CTD system is armed, the BCM activates the alarm. The CTD system uses the LH front door ajar switch as one method to activate the alarm. The driver door module (DDM) monitors the LH door ajar switch via a discreet input from the door ajar switch, if the DDM receives a ground signal from the LH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the RH front door ajar switch as one method to activate the alarm. The passenger door module (PDM) monitors the RH door ajar switch via a discreet input from the door ajar switch, if the PDM receives a ground signal from the RH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the rear compartment liftgate/liftglass ajar switchs as one method to activate the alarm. The liftgate module (LGM) monitors the liftgate and liftglass ajar switch via a discreet input from the ajar switch, if the LGM receives a ground signal from the liftgate or liftglass ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. Page 5018 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Only if necessary remove the fuel tank shield. IMPORTANT: Due to an access hole in the fuel tank shield, removal of the shield should not be necessary to access the fuel pressure service connection. 3. Remove the fuel pressure service connection cap, located near the fuel filter. 4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Turn ON the ignition. 6. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 8. Command the fuel pump ON with a scan tool. 9. Close the bleed valve on the fuel pressure gage. 10. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. Page 12916 Abbreviations And Meanings Part 5 Page 4939 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: Customer Interest Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 3409 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement (4.2L Engine) Removal Procedure 1. Remove the air cleaner resonator outlet duct. 2. Remove the transmission filler tube stud nut from the A.I.R. adapter and move filler tube out of the way. 3. Remove the oil level indicator tube. 4. Remove the oxygen sensor from the exhaust manifold. 5. Remove 4 manifold heat shield nuts and remove the heat shield. 6. Raise the vehicle. Refer to Vehicle Lifting. 7. Loosen and remove the exhaust pipe bolts from the exhaust manifold. 8. Lower vehicle. Recall - Spark Plug Misfire Condition Spark Plug: All Technical Service Bulletins Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Page 7433 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 9059 2. Remove the seat belt side buckle nut (2). 3. Remove the seat belt side buckle (1) from the seat. INSTALLATION PROCEDURE 1. Install the seat belt side buckle (1) to the seat with the seat belt anchor nut (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt side buckle nut to 55 N.m (40 lb ft). Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Ignition System - MIL ON/Misfire DTC's In Wet Weather Cowl Moulding / Trim: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 6772 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 12056 WA528F/76 - WA5322/33 Page 1964 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Drive Belt Excessive Wear Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Page 6869 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 9761 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Interior - Cargo Cover Handle is Broken Cargo Cover: Customer Interest Interior - Cargo Cover Handle is Broken Bulletin No.: 05-08-110-004A Date: May 02, 2006 TECHNICAL Subject: Cargo Cover Handle Broken (Replace Cargo Cover Handle - Service Part Available) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add the 2006 model year and the Saab 9-7X model information. Please discard Corporate Bulletin Number 05-08-110-004 (Section 08 - Body & Accessories). Condition Some customers may comment that the cargo cover handle is broken. Part returns have shown that the handle may be fractured at the locating pins. Correction DO NOT REPLACE THE CARGO COVER. Use the following steps the replace the cargo cover handle: 1. Using a flat-bladed tool, depress the two tabs that retain the handle to the cargo cover. 2. Remove the handle from the cargo cover. 3. Install the new handle to the cargo cover. Be sure that the two retaining tabs are released to secure the handle in position. Parts Information Page 13290 Registered And Non-Registered Trademarks Part 2 Page 10137 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 12786 Page 5820 8. Install the J8614-01 as shown. 9. Remove the pinion nut while holding the J8614-01. 10. Remove the washer. 11. Install the J8614-3 (2) and the J8614-2 (3) into the J8614-01 (1) as shown. 12. Remove the pinion yoke by turning the J8614-3 (3) clockwise while holding the J8614-01 (1). Use a container in order to retrieve the lubricant. 13. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J33782, 8.0 inch axle or the J38694 8.6 inch axle. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. Page 6154 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Description and Operation Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together. Page 13710 Windshield Wiper/Washer Switch (Turn Signal/Multifunction Switch C3) Page 5552 13. Slide the secondary lock (1) over the primary lock. 14. Be sure that the secondary lock tab (1) is securely in place. 15. Lower the vehicle. 16. Check the vehicle for proper operation. Page 7336 Fuse Block - Rear C2 Part 5 Service and Repair Parking Brake Actuator: Service and Repair Park Brake Actuator Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Disable the Park Brake Automatic Adjuster. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Remove the park brake cable from the mounting bracket by depressing the locking tabs. 5. Remove the rear park brake cable from the park brake actuator lever. 6. Remove the rear brake caliper and mounting bracket assembly. Page 4652 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Service and Repair Antenna Mast: Service and Repair FIXED ANTENNA MAST REPLACEMENT REMOVAL PROCEDURE 1. Unscrew the antenna mast. NOTE: Use tape on the tool surface so that you do not damage the paint on the antenna mast. 2. Remove the antenna mast from the antenna base. INSTALLATION PROCEDURE Page 11720 1. Position the trim panel to the vehicle. 2. Install the 12-volt power supply. 3. Connect the 12-volt power supply electrical connector. 4. Install the inflator bezel to the trim panel. 5. Feed the auxiliary air outlet through the hole in the inflator bezel. 6. Install the auxiliary air outlet washer and retaining nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 2 N.m (18 lb in). 7. Install the inflator switch to the inflator bezel. 8. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 9. Align the locating tabs on the trim panel to the holes in the body. 10. Seat the clips that retain the trim panel to the body. 11. Install the seat belt lower anchor. Tighten Tighten the anchor bolt to 70.0 N.m (52 lb ft). 12. Install the right rear door sill panel. 13. Install the liftgate sill plate. 14. Install the trim panel-rear quarter upper. Trim Panel Replacement - Rear Quarter - Right - 2 TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE Page 5780 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 4039 Engine Control Module: Diagrams Powertrain Control Module (PCM) C2 Powertrain Control Module (PCM) C2 Part 1 Page 450 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 3901 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 13876 For vehicles repaired under warranty, use the table. Disclaimer Page 2831 Registered And Non-Registered Trademarks Part 3 Page 2827 Abbreviations And Meanings Part 25 Page 4277 Abbreviations And Meanings Part 11 Page 11794 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 118 Page 499 4. Remove the electrical connectors from the VCIM. 5. Remove the VCIM from the vehicle INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. 2. Install the module to the upper bracket ensuring the retaining tab is fully seated. 3. Connect the 2 electrical connectors. NOTE: In order to avoid damage to the circuit board, do NOT over-tighten the thumb screws. Using your fingers, apply only a light pressure. Tighten Tighten the module thumb screw to a maximum of 0.2 N.m (2 lb in). Page 11502 Lower Side Moulding / Trim: Service and Repair Molding Replacement - Rear Panel (Trailblazer EXT, Envoy XL) Molding Replacement - Rear Panel (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the tail lamp assembly from the vehicle. 2. Release the 4 tabs that retain the trim to the tail lamp. 3. Remove the trim from the tail lamp. Installation Procedure 1. Install the trim to the tail lamp, ensuring that the retaining tabs are fully seated. 2. Install the tail lamp assembly to the vehicle. Service and Repair Fog/Driving Lamp Bulb: Service and Repair FOG LAMP BULB REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Turn the fog lamp switch to the OFF position. 2. Rotate the bulb socket counter clockwise in order to release the socket from the fog lamp housing. 3. Remove the socket from the fog lamp housing (2). 4. Remove the bulb from the socket. INSTALLATION PROCEDURE 1. Install the bulb to the socket. 2. Index the tabs on the bulb socket to the slots in the fog lamp housing. 3. Install the socket to the fog lamp housing (2). 4. Rotate the socket clockwise until fully seated. With Special Tools Fuel: Testing and Inspection With Special Tools TEST DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Alcohol concentrations of 10 percent or more in the fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation, lack of power, stalling, or no start. TEST PROCEDURE 1. Turn ON the J 44175 Fuel Composition Tester. 2. Verify the fuel composition tester is operational by measuring the AC frequency output with a DMM. Refer to Measuring Frequency in Diagnostic Aids. A frequency without a fuel sample in the test cell indicates that the tester is working correctly. 3. Install the fuel pressure gage. 4. Close the bleed valve on the fuel pressure gage. IMPORTANT: Bleed the fuel pressure gage a few times in order to obtain an accurate fuel sample from the vehicle being tested. 5. Place the bleed hose (1) of the fuel pressure gage into the 100 ml beaker (2). 6. Command the fuel pump relay ON with a scan tool. 7. Slowly open the bleed valve on the fuel pressure gage, until an adequate fuel sample is obtained. 8. If water appears in the fuel sample, clean the fuel system and replace the fuel in the vehicle. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 9349 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 7756 5. With the applicator hose down as far as possible toward the mating area of the serrations, spray a generous amount of grease. 6. Repeat the application after rotating the steering wheel 180 degrees, so that the serrations are treated in two locations opposite each other. 7. Position the floor air outlet duct into place and install the push pin retainer. 8. Raise the insulator panel and install the retaining clip to the IP substrate. 9. Install the two screws that retain the left closeout/insulator panel to the IP. Use the following steps to remove material from the upper intermediate shaft bushing. 1. Push the upper intermediate shaft boot seal (2) down toward the floor in order to completely expose the white bushing (1). 2. Using fine or very fine sandpaper, remove material from the intermediate shaft bushing. Sand around the entire face of the bushing sufficient enough to obtain clearance and reduce the drag between the intermediate shaft bushing and the upper boot seal. 3. Return the upper intermediate shaft boot seal to its original position. 4. Clean debris as necessary. Parts Information Warranty Information Page 13011 Abbreviations And Meanings Part 12 Page 715 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the electrical connectors from the EBCM (2). 2. Remove the four T 25-TORXmounting screws (1) that fasten the EBCM (2) to the BPMV (3). 3. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not use a tool to pry the EBCM or the BPMV. 4. Clean the BPMV (3) to EBCM (2) mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) on to the BPMV (3). Page 7895 Stabilizer Link: Specifications Stabilizer Shaft Link Retaining Nuts Front 74 ft. lbs. Rear 74 ft. lbs. Page 1390 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 2969 9. Wipe off any excess material from the bottom of the oil pan sealing area (1). 10. Install the fly wheel and secure with the bolts. Tighten the fly wheel bolts in sequence to 50 Nm (37 ft. lbs.) + 45 degrees. 11. Use the J 36660-A to tighten the bolts an additional 50 degrees. 12. Install the transmission. Page 6708 Registered And Non-Registered Trademarks Part 4 Bezel Replacement Front Door Panel: Service and Repair Bezel Replacement Door Handle Bezel Replacement Removal Procedure 1. Remove the door trim panel from the door. 2. Release the 4 tabs retaining the bezel to the trim panel. 3. Remove the bezel from the trim panel. Installation Procedure 1. Install the bezel to the door, ensuring that all 4 retaining tabs are fully seated. 2. Install the door trim panel to the door. Page 1770 Power Window Switch: Connector Views Window Switch - LR Page 12701 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 8291 Ambient Temperature Sensor / Switch HVAC: Service and Repair Intake Air Temperature Sensor Lower Left AIR TEMPERATURE SENSOR REPLACEMENT - LOWER LEFT REMOVAL PROCEDURE 1. Remove the IP assembly. 2. Disconnect the electrical connector from the air temperature sensor-lower left (2). 3. Remove the air temperature sensor-lower left. INSTALLATION PROCEDURE 1. Install the air temperature sensor-lower left (2). 2. Connect the electrical connector to the air temperature sensor-lower left. 3. Install the IP assembly. Lower Right AIR TEMPERATURE SENSOR REPLACEMENT - LOWER RIGHT REMOVAL PROCEDURE 1. Remove the passenger side closeout panel. 2. Remove the IP lower closeout panel. Locations Stop Lamp Switch Page 9425 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only HVAC Module Assembly Replacement Housing Assembly HVAC: Service and Repair HVAC Module Assembly Replacement HVAC MODULE ASSEMBLY REPLACEMENT TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6) Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 2. Recover the refrigerant. 3. Remove the I/P carrier. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel (I/P) Carrier Replacement 4. Reposition the heater hose clamps using J 43181. 5. Disconnect the heater hoses from the heater core. 6. Remove the retaining nut (3) from the accumulator (6) at the evaporator (1). 7. Disconnect the accumulator (6) from the evaporator (1). 8. Disconnect the evaporator tube (4) from the evaporator (1). 9. Disconnect all of the electrical connectors to the HVAC module assembly. 10. Remove the HVAC module assembly. INSTALLATION PROCEDURE 1. If replacing the HVAC module assembly (8), transfer the components from the old HVAC module assembly as necessary. 2. Install the HVAC module assembly (8). 3. Connect all of the electrical connectors to the HVAC module assembly. Page 7085 C108 Part 1 Page 9965 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Body VIN Code 6 Radiator: Service and Repair Body VIN Code 6 Radiator Replacement (Body Vin Code 6 / GMT 370) Tools Required J 41240 Fan Clutch Wrench - J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the coolant from the radiator. 2. Remove the lower radiator support shield, if equipped. 3. Remove the transmission cooler lines from the radiator. 4. Reposition the outlet radiator hose clamp using J 38185. 5. Remove the outlet radiator hose from the radiator. 6. Lower the vehicle. 7. Remove the cooling fan and shroud. 8. Remove the grille. 9. Remove the upper radiator to condenser bolts. 10. Remove the coolant recovery line from the radiator. 11. Lift upward on the condenser to remove from the radiator retaining tab. 12. Remove the radiator. Installation Procedure 1. Install the radiator. 2. Install the condenser to the radiator retaining tab. Page 11436 Liftglass Ajar Switch Page 10891 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ....................................... 334 - 375 kPa (48 - 54 PSI) Fuel Pressure Drop (After 1 minute) ............................................................................................................................................................. 34 kPa (5 PSI) Page 10652 Page 13893 Page 8274 3. Install the IP access cover. Page 11868 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Diagrams Transmission Range Switch Connector, Wiring Harness Side Page 12117 Page 9510 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 13975 Steps 11-12 Page 13389 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the windshield garnish moldings. 2. Remove the trim pad. 3. Disconnect the electrical connector from the sensor. IMPORTANT: Cover the windshield defrost vents with clean shop rags. 4. In order to remove the sensor from the trim pad, rotate the sensor counter-clockwise 1/4 turn. 5. Remove the sensor from the trim pad. INSTALLATION PROCEDURE Page 6964 Fuse Block - Rear C4 Part 3 Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 2195 Application Table Part 2 Page 501 Global Positioning System Module: Service and Repair Communication Interface Module Replacement 2 COMMUNICATION INTERFACE MODULE REPLACEMENT (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE 1. Fold and tumble the right second row seat to a cargo position. IMPORTANT: Do not exchange the vehicle communication interface module with other vehicles. Each vehicle communication interface module has a specific station identification (STID) and electronic serial number (ESN). These identification numbers are stored in the General Motors vehicle history files by VIN and used by OnStar(R) and the National Cellular Telephone Network. 2. Remove the protective cover (1) from the vehicle communication interface module (VCIM). 3. Remove the VCIM from the bracket by releasing the retaining tab (1). 4. Remove the electrical connectors from the VCIM. 5. Remove the VCIM from the vehicle. INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. 2. Position the VCIM near the mounting location. Page 8370 Various symbols in order to describe different service operations. Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 3815 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Page 12618 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Part 2 Page 8319 29. Install the auxiliary heater pump and bracket onto the dash panel studs. 30. Reinstall the HVAC plate and nuts. 31. On the coolant bypass valve, remove the hose (1) that went from the valve to the engine and discard. Page 10594 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 10416 Page 8371 Conversion - English/Metric Part 1 Page 11531 Skid Plate: Service and Repair Transfer Case Shield Replacement Transfer Case Shield Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield mounting bolts (3) from the transmission support. 3. Remove the transfer case shield (2) from transmission support. Installation Procedure 1. Install the transfer case shield (2) to the transmission support. Ensure that the J-nuts (1) are in place. Notice: Refer to Fastener Notice in Service Precautions. Page 4628 Fuel Injector: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel rail assembly. NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method. IMPORTANT: The engine oil may be contaminated with fuel if the fuel injectors are leaking. 2. Disconnect the fuel injector harness connector from the fuel injectors. 3. Remove the injector retainer clip (1). 4. Remove the fuel injector (3) from the fuel rail. 5. Discard the injector retainer clip (1). 6. Remove the injector O-ring seals (2, 4) from both ends of the injector. Discard the O-ring seals. INSTALLATION PROCEDURE IMPORTANT: When ordering new fuel injectors, be sure to order the correct injector for the application being serviced. The fuel injector assembly (1) is stamped with a part number identification (2). A four digit build date code (3) indicates the month (4), day (5), year (6), and the shift (7) that built the injector. Page 6161 Page 1366 Accelerator Pedal Position (APP) Sensor Page 9079 6. Remove the seat belt from the retractor bracket by guiding it through the slot. 7. Remove the rear seat belt center retractor retaining nut. 8. Remove the center retractor assembly by pulling the push pin from the seat back frame. 9. Remove the seat belt retractor bracket bolt (1) from the bracket and seat back frame. 10. Remove the seat belt retractor bracket from the seat back frame. INSTALLATION PROCEDURE Page 6771 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 12586 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat cushion bolts to 11 N.m (97 lb in). 5. Install the seat in the vehicle. Page 12230 Memory Seat Module - Driver C4 Part 2 Page 5154 Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side Page 4941 Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... ................................................ 18.0 Nm (13.0 lb. ft.) Spark Plug Gap ................................................ ..................................................................................................................................... 1.08 mm (0.0425 in.) Page 12200 Mirror Connector, Front Passenger Door Module (FPDM) - C3 Part 2 Page 2822 Abbreviations And Meanings Part 20 Page 10435 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. A/C - Stops Blowing Cold Air/Cycles ON and OFF Refrigerant: All Technical Service Bulletins A/C - Stops Blowing Cold Air/Cycles ON and OFF File In Section: 01 - HVAC Bulletin No.: 02-01-39-006A Date: May, 2003 INFORMATION Subject: Diagnosing Poor A/C Performance - A/C Stops Blowing Cold, A/C Cycles On and Off Models: 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL with Automatic or Manual HVAC Auxiliary Temperature Control (RPOs CJ2 or CJ3) This bulletin is being revised to include the underhood label part number. Please discard Corporate Bulletin Number 02-01-39-006 (Section 01 - HVAC). Some of the above listed vehicles may exhibit poor A/C performance due to an overcharged system. If the A/C system is overcharged, it may cause the A/C to stop blowing cold after extended idle or while driving in slow traffic at high ambient temperatures. It has been found that the underhood label containing the A/C charge specification is incorrect. The correct specification should read System Charge with Front and Rear -1.20 kg (2.65 lbs) Use this new charge specification whenever the A/C system is serviced. Install new label, P/N 15103173. Parts Information Parts are currently available from GMSPO. Disclaimer Page 1545 Impact Sensor: Diagrams Inflatable Restraint Side Impact Sensor (SIS) Inflatable Restraint Side Impact Sensor (SIS) - Left Page 6697 Abbreviations And Meanings Part 19 Page 6764 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9098 Impact Sensor: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. - Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. Page 12981 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 10972 1. Position the fascia to the vehicle impact bar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper retaining bolts to the fascia. Tighten the bolts to 2.5 N.m(22 lb in). 3. Install the screws that retain the fascia to the wheelhouse flanges. Tighten the screws to 2 N.m (18 lb in). 4. Install and fully seat the lower push-pins. 5. Install the backup lamp socket assemblies, if applicable. Page 3130 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................. AC 41-981 Page 12944 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 4235 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Door Window Channel Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Weatherstrip Run Channel Assembly Replacement - Rear (TrailBlazer EXT, Envoy XL) Window Weatherstrip Run Channel Assembly Replacement - Rear (TrailBlazer EXT, Envoy XL) Removal Procedure 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window regulator. 6. Carefully lower the glass into the door. 7. Remove the bolt (2) that retains the weatherstrip run channel to the door. 8. Pull the weatherstrip (1) loose from the window frame opening. 9. Release the clip retaining the quarter glass to the window opening by pulling forward on the run channel (4). Important: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip run channel assembly from the top of the door opening. Installation Procedure 1. Install the weatherstrip/run channel assembly to the door. 2. Install the quarter glass into the window opening by pressing the window channel (4) rearward until the retaining clip is fully installed. 3. Press the weatherstrip (1) into the window frame opening. 4. Position the tabs on the weatherstrip into the slots on the door. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten the bolt to 10 N.m (88 lb in). 6. Install the window glass into the run channel, slide up to the closed position, tape the window to the door frame. Page 6683 Abbreviations And Meanings Part 5 Page 5704 Page 10821 Page 13759 Parts are currently available from GMSPO. Disclaimer Description and Operation Fuel Filler Cap: Description and Operation NOTE: If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system. The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being over-tightened. To install the cap, turn the cap clockwise until you hear audible clicks. This indicates that the cap is correctly torqued and fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system. Page 770 Page 3343 3. Install the coolant recovery line to the radiator. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 4. Install the bolts retaining the condenser to the radiator. Tighten the bolts to 28 Nm (21 ft. lbs.). 5. Install the grille. 6. Install the cooling fan and shroud. 7. Raise the vehicle. 8. Install the outlet radiator hose (1) to the radiator. 9. Reposition the outlet radiator hose clamp (1) using J 38185. 10. Connect the transmission cooler lines to the radiator. Page 7582 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Specifications Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 6967 Fuse Block - Underhood C1 Part 3 Page 1209 Engine Oil Level And Temperature Sensor Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Press tabs (1) inward and lift to remove the junction block cover. 3. Pull upward on the fuse relay center cover (1) to release the retaining tabs and remove the cover. 4. Note the location and remove the harness end bolts (2) and remove the harness ends from the fuse relay center. 5. Remove the fuse relay center bolts (3) and remove the fuse relay center from the junction block bracket. 6. Pull downward on the wiring harness ends to remove from the bottom of the fuse relay center. Page 10496 Page 7979 Tighten Tighten the shock module yoke to lower control arm retaining nut to 110 N.m (81 lb ft). Install the tire and wheel. Refer to Tire and Wheel Removal and Installation. Lower the vehicle. Disclaimer Page 14006 Page 7300 Auxiliary Power Outlet - Rear Page 12787 Page 4486 1. If replacing the purge bracket, install the purge valve bracket and the attaching bolt (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the purge valve mounting bracket attaching bolt to 10 N.m (89 lb in). 2. Install purge valve (2) on to the purge valve mounting bracket. 3. Connect the EVAP purge pipe to the EVAP canister purge valve. 4. Connect the engine vacuum pipe to the EVAP canister purge valve. 5. Connect the electrical harness connector (2) to the EVAP canister purge valve (1). 6. Lower the vehicle. Page 12865 Page 6936 Application Table Part 1 Locations Steering Column Page 4565 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator support diagonal brace if applicable. 2. Remove the radiator air intake baffle if applicable. 3. Loosen the three air cleaner cover/resonator retaining screws (2) one shown, and remove the cover/resonator (1). 4. Lift the air cleaner element (1) and air outlet duct (3) from the lower air cleaner housing/washer solvent tank assembly (2). 5. Remove the air cleaner element (1) by grasping the air cleaner element and removing it from the air outlet duct (3) with a twisting and pulling motion. 6. Inspect the entire assembly for debris or damage and repair as necessary. INSTALLATION PROCEDURE Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: Customer Interest Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3775 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator support diagonal brace if applicable. 2. Remove the radiator air intake baffle if applicable. 3. Loosen the three air cleaner cover/resonator retaining screws (2) one shown, and remove the cover/resonator (1). 4. Lift the air cleaner element (1) and air outlet duct (3) from the lower air cleaner housing/washer solvent tank assembly (2). 5. Remove the air cleaner element (1) by grasping the air cleaner element and removing it from the air outlet duct (3) with a twisting and pulling motion. 6. Inspect the entire assembly for debris or damage and repair as necessary. INSTALLATION PROCEDURE Page 857 Abbreviations And Meanings Part 2 Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Page 12488 Page 7276 Abbreviations And Meanings Part 12 Page 7358 Fuse Block - Underhood C4 Part 1 Page 1510 40.6. Install the ring terminal (orange wire) to the underhood fuse block stud (1). 40.7. Locate circuit no. 241 or 441 (ignition 3 brown wire) (PIN B11 or C11) in the existing underhood fuse block harness (1) of C2 (2) and splice bare wire to it using a splice clip. Wrap with electrical tape. 40.8. Locate connector C105 (3), located on the left side inner fender. Separate the connector halves. On the female side of the connector, remove the terminal from cavity F (gray/black wire) and tape back. 40.9. Install the terminal end on the pump wiring harness into cavity F of connector C105. 41. Install the evaporator tube and nut to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 42. Install the coolant recovery reservoir with the accumulator attached. 43. Install the nut and bolt securing the coolant recovery reservoir. 44. Install the coolant hoses to the coolant recovery reservoir. 45. Install the nut retaining the accumulator to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 46. Install the compressor suction hose assembly to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). Page 7763 12. Disconnect the lower intermediate shaft boot from the power steering gear and remove the intermediate shaft boot from the vehicle. Important: Note the relationship of the intermediate shaft to the power steering gear and the intermediate shaft to the steering column in order to ensure proper installation. 13. Remove the lower intermediate shaft to the power steering gear input shaft pinch bolt. 14. Disconnect the lower intermediate shaft from the power steering gear. 15. Remove the lower intermediate shaft from the vehicle. 16. Replace the lower intermediate shaft, P/N 15155707. Parts Information Warranty Information Page 13407 Canadian dealers should refer to the Canadian distribution of the bulletin for detailed claim information. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Page 13158 Registered And Non-Registered Trademarks Part 4 Page 10356 Abbreviations And Meanings Part 9 Page 9527 Page 11226 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Rear Door Window Belt Inner Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Inner Removal Procedure 1. Open the door. 2. Remove the door trim panel. 3. Starting at the back of the strip, carefully lift the strip off the pinch-weld flange until the strip is completely released. Installation Procedure 1. Install the sealing strip to the pinch-weld flange. Ensure that the strip is fully seated. 2. Install the door trim panel. 3. Close the door. Rear Door Window Belt Outer Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure 1. Remove the screw that retains the sealing strip to the door. 2. Lift upward on the forward edge of the sealing strip. 3. Remove the sealing strip from the pinch-weld flange. Installation Procedure Page 6701 Abbreviations And Meanings Part 23 Page 790 Location View Page 13110 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 7185 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Diagram Information and Instructions Door Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 661 Memory Seat Module - Driver C3 Part 3 Page 461 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 1335 Miniwedge (Door Jamb Switch) - RR Page 9334 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 12244 Liftgate Module (LGM) C3 (Except XUV) Page 13120 Conversion - English/Metric Part 2 Page 6908 Abbreviations And Meanings Part 23 Page 6893 Abbreviations And Meanings Part 8 A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Page 6939 Location View Page 882 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 9092 Page 11835 Abbreviations And Meanings Part 20 Page 348 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Page 2391 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 2633 9. Remove the camshafts. 10. Using a suitable adapter, apply air pressure to the cylinder. 11. Install the J 44228 and compress the valve 12. Remove the valve keys. 13. Remove the J 44228. Page 13154 Abbreviations And Meanings Part 26 Page 156 Disclaimer Page 621 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 6274 Notice: Refer to Fastener Notice in Service Precautions. 7. Install the lower brake caliper mounting bolt. ^ Tighten the brake caliper mounting bolt to 51 Nm (38 ft. lbs.). 8. Install the tire and wheel assembly. 9. Lower the vehicle. Refer to Vehicle Lifting. 10. Fill the brake master cylinder reservoir. Caution: Refer to Firm Brake Pedal Caution in Service Precautions. 11. Pump the brake pedal slowly and firmly to seat the brake pads. 12. Burnish the new brake pads. Rear Brake Pads Replacement- Rear Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Inspect the brake fluid level in the brake master cylinder reservoir. 2. If the brake fluid is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. Page 9522 Page 6028 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector.Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON transmission fluid. Page 2254 Fuse Block: Application and ID Fuse Block - Rear (Short Wheelbase) Location View Page 7965 3. Remove the fuel fill pipe bracket nut (2). 4. Raise and suitably support the vehicle. 5. Remove the fuel fill pipe ground strap bolt. 6. Cut off the ground strap ring terminal and tie strap. 7. Loosen the fuel hose clamp (8). 8. Remove the fuel fill upper pipe (7) from the vehicle. 9. Install the new fuel fill upper pipe into the vehicle. Use P/N 88983256 for 2002-2003 model year vehicles or P/N 15131043 for 2004 model year vehicles. 10. Tighten the fuel hose clamp. Tighten Tighten the clamp to 2.5 N.m (22 lb in). 11. Wrap the excess length of ground strap around the fuel hose as necessary. 12. Install the fuel fill pipe ground strap bolt in its original location. 13. Loosen the fuel hose clamps (1, 3). 14. Remove the lower fuel hose (2) from the vehicle. 15. Install the new lower fuel hose into the vehicle. 16. Tighten the lower fuel hose clamps. Tighten Page 7067 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 90 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION RETAINED ACCESSORY POWER (RAP) POWER MODE RAP is a power mode that permits the operation of selected customer convenience items for 10 minutes after the ignition switch is turned OFF. RAP power mode is enabled by the BCM. The BCM: controls certain body functions. - sends out a class 2 message via the serial data line, which enables/disables other modules at the beginning/end of RAP power mode. Some BCM features, such as the interior courtesy lamps will function after the 10 minute RAP time limit has elapsed. This is normal, and does not mean RAP power mode is malfunctioning. The BCM enables the following functions in RAP Power Mode: The sunroof (internal to BCM - if equipped) - The right and left power rear windows (internal to BCM - if equipped) - Any class 2 module that functions in RAP power mode (that is not hard-wired), is controlled by the BCM via class 2 power mode messages. EXAMPLE: the radio works in RAP power mode due to the BCM allowing and controlling it. RAP is disabled when: The door is opened. - A low battery voltage is detected by the BCM. - The transition of ignition switch from OFF to ON or ACC. - 10 minutes have elapsed after the ignition was turned OFF. - There may be some functions of the vehicle that are hard-wired straight to the battery, these are the exceptions. The BCM monitors the ignition switch position, battery voltage and passenger compartment door status to determine whether RAP power mode should be enabled. If the ignition switch transitions from ON to OFF, the battery voltage is within the acceptable range and the passenger compartment doors are closed, the BCM enables RAP power mode. After the 10 minutes has elapsed, the BCM sends a class 2 message to the serial data network. This message commands the other modules to stop functioning, that are power moded by the BCM. RAP RELAY (IF EQUIPPED) The long base vehicles (GMT370), with third row seating, will have a RAP relay (RAP relay is also on the G/H Van). Due to this, the BCM will power/enable a relay. On the short based vehicles (GMT360), the RAP output only needs to drive the sunroof. The BCM is able to supply enough current to operate the sunroof by itself, so a relay is not needed. Although, on the GMT370/longbase vehicle, there are optional powered rear quarter vent windows, which are also enabled in RAP power mode. Refer to Retained Accessory Power (RAP) Schematics for the applicable schematics for RAP on both vehicle types. On the GMT370/longbase vehicle, the BCM is not able to supply enough current to both rear quarter vent windows and the sunroof at the same time (if equipped with both options). This is the purpose of the RAP relay. The BCM energizes the RAP relay coil, which allows a fused power supply to the sunroof and the rear quarter vent windows. Page 4721 8. Install the fuel fill pipe bracket nut (2). Tighten Tighten the nut to 10 N.m (89 lb in). 9. Install the fuel fill pipe housing. 10. Install the fuel fill cap. Page 4198 Oil Pressure Sensor: Diagrams Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Diagram Information and Instructions Starter Motor: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 2762 Front Suspension Control Arm: Service and Repair Front Suspension Lower Control Arm Bracket Replacement Lower Control Arm Bracket Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the stabilizer shaft link lower retaining nut. 4. Disconnect the stabilizer shaft link and washer from the lower control arm. 5. Remove the lower control arm to lower control arm bracket mounting nuts. Important: Note the direction the bolts are removed for reinstallation. 6. Remove the lower control arm to lower control arm bracket mounting bolts. Important: Take care not to disengage the axle shaft from the transmission. Strut Replacement - Liftgate Trunk / Liftgate Shock / Support: Service and Repair Strut Replacement - Liftgate Strut Replacement - Lift Gate Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open and support the liftgate. Notice: Refer to Liftgate/Hood Assist Rod Notice in Service Precautions. 2. Lift up the retainer clips on the liftgate struts using a small flat-bladed tool. 3. Remove the upper end of the liftgate struts from the ball joint. 4. Remove the lower end of the liftgate struts from the ball joint. 5. Remove the liftgate struts from the liftgate. Installation Procedure 1. Position the liftgate struts to the liftgate. 2. Install the upper end of the liftgate struts to the ball joint. Press in to place until fully seated. 3. Install the lower end of the liftgate struts to the ball joint. Press in to place until fully seated. 4. Remove the support device from the liftgate. 5. Close the liftgate. Locations Fuel Tank Pressure Sensor: Locations Fuel Tank Locations Upper Console Page 10056 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 9400 Driver/Vehicle Information Display: Electrical Diagrams Driver Information Diagram Page 11952 Power Mirror Switch: Service and Repair POWER MIRROR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Carefully use a flat-bladed tool in order to release the outside mirror switch retaining tabs from the trim panel. 2. Remove the outside mirror switch from the trim panel. 3. Disconnect the electrical connector from the power folding mirror switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power folding mirror switch. 2. Position the power folding mirror switch to the door trim panel. 3. Apply downward pressure to the power folding mirror switch, ensuring the retaining tabs are fully seated. Page 6134 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. 1. Raise the vehicle. 2. Remove tire and wheel. 3. Remove brake caliper. 4. Remove the hub and rotor. 5. Remove wheel speed sensor mounting clip on the control arm. 6. Remove wheel speed sensor mounting clip on the frame rail. 7. Disconnect the wheel speed sensor electrical connector (2). 8. Remove the sensor mounting screw (5). Important: The wheel speed sensor mounts into a bore that leads to the center of the sealed bearing. Use caution when cleaning or working around the bore. Do not contaminate the lubricant inside the sealed bearing. Failure to do so can lead to premature bearing failure. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device. Prying will cause the sensor body to break off in the bore. Notice: Do not attempt to remove the stainless steel shim from the bearing assembly. The shim is permanently attached. If the shim is damaged or bent, replace the bearing assembly. Failure to comply will result in diminished sensor and ABS performance. 9. Remove wheel speed sensor from hub and bearing assembly. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The new speed sensor will have a new O-ring. Dispose of the old O-ring. Lubricate the new O-ring lightly with bearing grease prior to installation. You may also lubricate the sensor just above and below the new O-ring. DO NOT lubricate the bore. Page 20 Page 13910 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 8617 Heater Control Valve: Service and Repair COOLANT BYPASS VALVE REPLACEMENT TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 2. Remove the coolant recovery reservoir. 3. Using the J 43181, disconnect the inlet heater hose from the heater core. 3.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 3.2. Close the tool around the inlet heater core hose. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 4. Position the hose clamp at the engine outlet using J 38185. 5. Remove the heater inlet hose (4) from the engine block. 6. Remove the nut retaining the coolant bypass valve to the cowl. 7. Remove the vacuum hose from the coolant bypass valve. 8. Remove the coolant bypass valve. 9. Position the clamps at the coolant bypass valve. 10. Remove the heater inlet hoses form the coolant bypass valve. INSTALLATION PROCEDURE Ignition System - MIL ON/Misfire DTC's In Wet Weather Ignition Coil: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 10242 1. Install the processor bracket to the rear seat studs. 2. Install the nut to the rear seat back stud. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 45 N.m (33 lb ft). 3. Position the upper bracket to the processor bracket. 4. Slide the upper bracket outboard until all the retaining tabs are seated to the processor bracket. 5. Install the communication interface module. 6. Install the right rear seat cushion. Page 6677 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required A/T - Cooler Line Fitting Applications Fluid Line/Hose: All Technical Service Bulletins A/T - Cooler Line Fitting Applications Bulletin No.: 08-07-30-004 Date: January 31, 2008 INFORMATION Subject: 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70 M32, M33, MK2 MD6) Oil Cooler Fitting Change Models: 1997-2008 GM Light Duty Trucks (Including Saab) with 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70, M3, M33, MK2, MD6) Aluminum cooler line fittings - These new fittings (2) cannot be used on earlier cases because the threaded hole is not the same size. Old style fittings (1) will continue to be available through SPO parts. Service cases will be the new case and fittings. The old cases with the old thread design will not be maintained for service. The connection on the hose side will accept both the short snout and the newer longer snout cooler hose assemblies. The fittings (1) have a new torque specification of 20 N.m (14 lb ft). They also have one inner and one outer "0" ring that are not serviced separately. Page 11601 3. Remove the third row rear seats. 4. Remove the front door sill plates. 5. Remove the rear door sill plates. Notice: Remove the headliner and the headliner harness as an assembly. Do NOT cut or splice the headliner harness. Cutting or splicing the harness may damage the coax cable, resulting in poor radio performance. 6. Remove the center pillar trim panels. 7. Remove the lift gate door sill plate. 8. Remove the left/right front body side window garnish molding. 9. Remove the left/right rear body side window garnish molding. 10. Remove the bolts from the cargo tie-down loops. 11. Remove the nut (1), securing the stowage jack carrier to the wheelhouse panel. 12. Loosen the three bolts that secure the jack carrier to the vehicle. 13. Remove the carpet from around the wheel stud. 14. Remove the body electrical block. 15. Remove the body electrical block electrical connectors back through the hole in the carpet. 16. Pull the communication interface module electrical connectors back through the hole in the carpet. 17. Remove the floor console to the floor console carrier. 18. Remove the 4 nuts (2) retaining the rear of the floor console bracket to the floor weld studs. 19. Raise the rear portion of the floor console bracket and remove the carpet from underneath the console bracket. 20. Remove the carpet from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. Page 9190 Abbreviations And Meanings Part 23 Page 5855 7. Align the hole in the pinion shaft with the bolt hole in the differential case. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the new pinion shaft locking bolt. Tighten the pinion shaft locking bolt to 36 Nm (27 ft. lbs.). 9. Install the rear axle housing cover and the gasket. 10. Install the brake caliper. 11. Install the tire and wheel assembly. 12. Fill the rear axle with axle lubricant. Use the proper fluid. 13. Lower the vehicle. Page 12680 Disclaimer Page 9811 Abbreviations And Meanings Part 3 Page 13278 Abbreviations And Meanings Part 16 Page 13456 Northface Cargo Lamp Page 12418 10. Remove the SIR wiring harness (1) from the seat back frame. 11. Remove the lumbar wiring harness (3) from the seat back frame. 12. Remove the wiring harness clips (2) from the seat back frame. INSTALLATION PROCEDURE 1. Install the wiring harness clips (2) to the seat back frame. 2. Install the lumbar wiring harness (3) to the seat back frame. 3. Install the SIR wiring harness (1) to the seat back frame. 4. Install the side impact module tub to the seat back frame with 2 push pins (1). Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: Customer Interest Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Oil Viscosity Engine Oil: Description and Operation Oil Viscosity ENGINE OIL VISCOSITY, UNITED STATES AND CANADA NOTICE: Using oils of any viscosity other than those recommended could result in engine damage. When choosing an oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Then, select the recommended oil viscosity. SAE 5W-30 is the only viscosity grade recommended for your vehicle. Use only oils which have the API Starburst symbol and which are also identified as SAE 5W-30. If the temperature range is-18°F( 0°C) or above SAE 10W-30 oil which has the API Starbust symbol is acceptable if SAE 5W 30 oils is not available. Areas where the temperature falls below -29°F (-20°C), either an SAE 5W-30 synthetic oil or and SAE 0W-30 oil is recommended. Both will provide easier cold starting and better protection for the engine at extremely low temperatures. Do not use other viscosity grade oils, such as SAE 10W-40 or SAE 20W-50 under any conditions. SAE 5W-30 is the recommended engine oil viscosity. Engine oil viscosity thickness has an effect on the fuel economy and the cold-weather operation engine starting and oil flow. Lower viscosity engine oils can provide better fuel economy and cold-weather performance. However, higher temperature weather conditions require higher viscosity engine oils for satisfactory lubrication. When the temperature is consistently above -18°C (0°F), 10W-30 may be used. SAE 20W-50 or oils of other viscosity rating or quality designations are NOT recommended for use in any GMC vehicle at any time. ENGINE OIL QUALITY AND VISCOSITY (OTHER THAN THE UNITED STATES AND CANADA) NOTICE: Using oils of any viscosity other than those recommended could result in engine damage. When choosing an oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Then, select the recommended oil viscosity. Description and Operation Air Cleaner Restriction Indicator: Description and Operation The air cleaner restriction indicator is located on the intake duct between the air cleaner assembly and the throttle body. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Page 2026 1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185. 4. Install the heater outlet hose (3) to the heater core (1). 5. Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Install the transmission. 7. Install the coolant bypass valve. Page 6920 Auxiliary Power Outlet - Front Page 1937 Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... ................................................ 18.0 Nm (13.0 lb. ft.) Spark Plug Gap ................................................ ..................................................................................................................................... 1.08 mm (0.0425 in.) Wheel Alignment Specifications Page 5481 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 9861 Global Positioning System Antenna: Description and Operation CELLULAR AND NAVIGATION ANTENNAS This vehicle will be equipped with either separate cellular and navigation antennas, or a combination cellular and navigation antenna, which brings the functions of both into a single part. The cellular antenna is the component that allows the OnStar(R) system to send and receive data over airwaves by means of cellular technology. This antenna is connected at the base to a coax cable that plugs directly into the VCIM. The navigation antenna is used to collect the constant signals of the orbiting satellites. Within the antenna, is housed a low noise amplifier that allows for a more broad and precise reception of this data. Current GPS location is collected by the module every time a keypress is made. The OnStar(R) Call Center also has the capability of pinging the vehicle during an OnStar(R) call, which commands the module to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged. In the event the VCP loses or is removed from power, this history location is used by the OnStar(R) Call Center as a default. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. This antenna requires a clear and unobstructed path to the satellites in the sky. Window tinting on vehicles may interfere with the GPS sensor functions, depending upon the amount of darkening and/or metallic particles that are embedded in the film of the tinting material. Application and ID Relay Box: Application and ID Location View Application Table Part 1 Page 12560 Registered And Non-Registered Trademarks Part 2 Page 2510 4. Install the camshaft caps and bolts. ^ Tighten the camshaft cap bolts to 12 Nm (106 inch lbs.). 5. Remove the J 44221 6. Carefully move the sprockets back onto the camshafts and remove the J 44222. 7. Install the intake camshaft sprocket washer and bolt, and the exhaust camshaft actuator bolt. ^ Tighten the intake camshaft sprocket bolt the first pass to 20 Nm (15 ft. lbs.). ^ Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass an additional 100°. ^ Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 ft. lbs.). ^ Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135°. 8. Install the camshaft cover. Page 769 Page 9555 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 4095 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 2157 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. See: Heating and Air Conditioning/Compressor HVAC/Service and Repair See: Heating and Air Conditioning/Service and Repair/Flushing Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. See: Heating and Air Conditioning/Specifications/Capacity Specifications Page 7143 12. Disconnect the body wiring harness connector (1) from the junction block. 13. Disconnect the headliner harness connector (2) from the junction block. 14. Disconnect the console harness connector from the junction block. 15. Remove the block base retaining nuts from the floor studs. 16. Remove the block base from the floor panel. INSTALLATION PROCEDURE 1. Install the block base to the floor studs. 2. Install the block base retaining nuts to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the block base retaining nuts to 10 N.m (88 lb in). 3. Connect the console harness connector to the block base. 4. Connect the headliner harness connector (2) to the block base. 5. Connect the body wiring harness connector (1) to the block base. Page 6675 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Locations Instrument Panel Page 9315 Driver/Vehicle Information Display: Locations Steering Wheel Controls Page 12167 Abbreviations And Meanings Part 12 Page 12325 3. Remove the head restraint guides by squeezing the retaining tabs (1) located at the bottom of the guides together. INSTALLATION PROCEDURE 1. Install the head restraint guides by pushing the guides into the frame until the retaining tabs (1) lock the guide in place. 2. Install the seat back cover and pad to the seat back. 3. Install the head restraint. Head Restraint Retractor Assembly Replacement - Rear No. 1 HEAD RESTRAINT RETRACTOR ASSEMBLY REPLACEMENT - REAR NO. 1 REMOVAL PROCEDURE 1. Remove the seat back cover and pad. CAUTION: Refer to Prevent Accidental Deployment of the Head Restraint Retractor Assembly in Service Precautions. Page 4295 Registered And Non-Registered Trademarks Part 3 Page 7490 C312 Part 1 Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 11418 6. Using a 2.0 mm (0.08 in) pin (1), secure the window bracket (3) to the window frame (4). INSTALLATION PROCEDURE 1. Position the actuator over the mounting studs and install the retaining nuts (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts (3) to 7 N.m (2 lb in). 2. Connect the electrical connector (1). 3. If installing or adjusting the old actuator proceed as follows: IMPORTANT: If installing a new actuator, the actuator is timed correctly at the factory. 4. Ensure the window latch bracket (3) is pinned (1) the window frame (4). Page 4955 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Page 12578 Heated Seat Element And Thermistor Assembly - Front Passenger Back Specifications Compressor Clutch: Specifications CLUTCH GAP Information not supplied by the manufacturer. Page 6798 Abbreviations And Meanings Part 2 Page 2636 6. Remove the air pressure to the cylinder. 7. Coat the camshaft journals, the camshaft journal thrust face, and the camshaft lobes with clean engine oil. 8. Install the camshafts to their original position. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 9. Install the camshaft caps onto their original journal. Tighten the camshaft cap bolts to 12 Nm (106 inch lbs.). 10. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222. 11. Install the intake camshaft sprocket washer and the bolt, and the exhaust camshaft actuator bolt. - Tighten the intake camshaft sprocket bolt the first pass to 20 Nm (15 ft. lbs.). - Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100°. - Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 ft. lbs.). - Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135°. Page 11832 Abbreviations And Meanings Part 17 Page 13716 Miniwedge (Door Jamb Switch) - RF Page 1347 1. Position the headlamp switch near the access hole. 2. Connect the electrical connectors to the headlamp switch. 3. Install the headlamp switch to the IP. Ensure that the retaining tabs are fully seated. 4. Install the left IP access cover. Page 10667 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 3939 Abbreviations And Meanings Part 26 Page 11034 10. Place the hinge (1) into position and hand tighten the two attaching bolts. 11. Remove the feed wire from the hinge. 12. Install and hand tighten the two remaining bolts. 13. Align the hinge to the original scribe location and torque all four bolts to 25 N.m (18 ft.lb). 14. Clean and prepare all bare-metal surfaces. 15. Apply a full-bodied caulk around the service hinge (1). Locations Memory/Heated Seat Switches Page 6706 Registered And Non-Registered Trademarks Part 2 Page 4091 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Description and Operation Fuel Gauge: Description and Operation FUEL GAGE The IPC displays the fuel level as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the fuel level percent. The fuel gage defaults to empty if: - The PCM detects a malfunction in the fuel level sensor circuit. - The IPC detects a loss of class 2 communications with the PCM. When the fuel level is less than a pre-determined value, the IPC illuminates the low fuel indicator. Page 6086 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11323 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6815 Abbreviations And Meanings Part 19 Page 51 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 13283 Abbreviations And Meanings Part 21 Page 10631 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 7717 For vehicles repaired under warranty, use the table. Disclaimer Service and Repair Memory Positioning Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the 3 seat switch bezel screws. 2. Remove 4 nuts that attach the seat pan to the seat assembly. 3. Remove the clip from the front outboard seat pan stud. Discard the clip. 4. Lift the seat pan up in order to allow access to the seat control module retaining screw. 5. Remove the seat control module retaining screw. 6. Disconnect the electrical connectors from the seat control module as necessary. 7. Remove the seat control module from the seat assembly. INSTALLATION PROCEDURE 1. Align and install the locating tabs on the seat control module with the seat pan. 2. Connect the electrical connectors to the seat control module as necessary. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 2861 valve would indicate a faulty pump. Page 8693 Do NOT replace an EV fan unless a specific condition related to the EV fan is identified using SI diagnostics. If the fan has a condition that warrants replacement, a DTC should set and/or SI diagnostics should lead to the replacement of the fan clutch. If the fan is not operating at the proper speed/function, the appropriate diagnostic trouble code should set. Identify the root cause of the condition. Please make sure to do a thorough review of SI for proper diagnostics. Several Service Bulletins and Preliminary Information are available on SI regarding the EV fan. Refer to "Operating Characteristics" and "Diagnostic Tips" in this bulletin for additional information. Operating Characteristics of the Electro-Viscous (EV) Fan Clutch Changes to the EV fan clutch to improve the HVAC performance basically increase airflow in certain conditions. It is now possible during start up for the EV fan clutch to be engaged and match engine speed for about 1 minute depending on driving speeds (with lower speeds having a longer disengagement time) producing some noise/flare. The noise/flare will most likely be intermittent and can be dependent on the following conditions: ^ Fan clutch valve orientation, with check ball at 11:00 position as viewed from front of vehicle when the engine is stopped. ^ HVAC or powertrain cooling conditions when the vehicle is shut off. ^ Parking incline - vehicles parked nose up on a 16% or higher incline (such as vehicles coming off transport or parked on steep driveways) may have prolonged fan noise/flare until the fluid is pumped out of the working chamber of the fan. These conditions can occur in as little as ten minutes. Once the vehicle is not parked in these conditions, it should operate as expected. ^ Please note that if the vehicle is parked nose down with a 16% or more decline, the EV fan clutch may have a delayed engagement response similar to what is described in Corporate Bulletin Number 04-01-38-019A. Important: Do not replace EV fan clutches for these conditions listed above; they are expected vehicle characteristics. If the fan clutch is truly operating at a speed higher than intended, a DTC P0495 or P1484 should set. Additional codes are available for other conditions. Diagnostic Tips Depending on the vehicle year, the Tech 2(R) may allow some EV fan control using the special functions application of the Tech 2 (refer to the proper SI documentation). If this function or a fused jumper wire is being used to check EV fan response, there may be a delay in fan response (up to 2-3 minutes depending on conditions, please refer to SI diagnostics). The desired fan speed and actual fan speed data (on the Tech 2(R)) can be misleading. The desired fan speed is comprised of the maximum of multiple parameters (for example engine coolant temp, A/C pressure, etc.) and may not be the ruling desired fan speed parameter. The end result may be that the actual desired fan speed is lower than what is displayed. Additionally, the desired fan speed may be higher than the current engine speed. The fan is limited by the current engine RPM and will max out at about 3500 RPM under full manual fan engagement request along with a corresponding engine RPM speed. The 4.2L 1-6 (LL8) engine's desired and actual fan speeds will usually be closer to each other than the 5.3L V-8 (LM4 or LH6) or the 6.0L V-8 (LS2). Disclaimer Page 13925 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 9554 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 10371 Abbreviations And Meanings Part 24 Page 12148 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 1078 Passlock Sensor Page 955 Powertrain Control Module (PCM) C3 Part 4 Page 454 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 10562 Labor Time Information Page 8904 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 4. Install the LF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Page 10364 Abbreviations And Meanings Part 17 Page 6624 6. Disconnect the positive cable lead from the generator (1). INSTALLATION PROCEDURE 1. Install the new positive cable to the generator and secure the positive cable with the nut (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the positive cable bolt to 9 N.m (80 lb in). 2. Connect the positive cable to the junction block and secure the positive cable with the bolt. Tighten Tighten the positive cable nut to 10 N.m (89 lb in). 3. Connect the positive cable to the starter and secure the positive cable with the nut. Tighten Tighten the nut 9 N.m (80 lb in). 4. Connect the harness to the engine harness bracket. 5. Connect the cable to the positive battery post. Tighten Tighten the battery positive bolt to 15 N.m (11 lb ft). 6. Connect the battery negative cable. Page 3188 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Page 8813 3. Remove the air temperature sensor. 4. Disconnect the electrical connector (2) from the upper air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the upper air temperature sensor (1) to the air duct (2). 2. Connect the electrical connector (2) to the upper air temperature sensor (1). 3. Install the upper air temperature sensor. 4. Install the HVAC control module. 5. Install the radio. Upper Right AIR TEMPERATURE SENSOR REPLACEMENT - UPPER RIGHT REMOVAL PROCEDURE 1. Remove the radio. Page 9834 Abbreviations And Meanings Part 26 Page 8356 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 1416 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Page 3680 Park/Neutral Position Switch (C2) Page 10729 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 12422 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Rear No. 1 - 2 SEAT BACK FRAME REPLACEMENT - REAR NO. 1 (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE 1. Remove the screws from the inboard/outboard rear seat back cushion hinge covers. 2. Remove the seat back cover and pad. 3. Remove the push pins (1) securing the seat back panel to the frame. 4. Remove the seat back panel. 5. Remove the rear center seat belt retractor assembly, if you are removing the frame from the left-hand rear seat. Page 10856 Conversion - English/Metric Part 2 Page 2658 Drive Belt Chirping Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Page 10644 Page 10895 Registered And Non-Registered Trademarks Part 5 Page 13608 Hazard Warning Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the left closeout/insulator panel. 2. Remove the flasher retaining bracket from the insulator panel. 3. Disconnect the flasher from the electrical connector. 4. Remove the flasher from the vehicle. INSTALLATION PROCEDURE 1. Position the flasher to the insulator panel. 2. Connect the electrical connector to the flasher. 3. Install the flasher retaining bracket to the insulator panel. 4. Install the left closeout/insulator panel. Page 4756 Fuel Tank Unit: Description and Operation FUEL SENDER ASSEMBLY Fuel Sender Assembly The fuel sender assembly consists of the following major components: - The fuel pump (1) - The float (2) - The fuel level sensor (3) Page 4776 Throttle Body: Service and Repair THROTTLE BODY ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the resonator assembly. 2. Remove the evaporative emission (EVAP) canister purge line from the throttle body. 3. Disconnect the throttle body electrical connector. 4. Remove the throttle body assembly retaining bolts (1). 5. Remove the throttle body assembly (2) and the gasket from the intake manifold. 6. Clean the gasket surface. INSTALLATION PROCEDURE 1. Install the throttle body assembly (2) to the intake manifold with the gasket. 2. Install the throttle body assembly retaining bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Connect the throttle body electrical connector. 4. Install the EVAP canister purge line to the throttle body. 5. Install the resonator assembly. Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity TrailBlazer 13.9 quarts 13.1 liters TrailBlazer EXT 15.2 quarts 14.4 liters Page 9540 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. The scan tool instructs you to perform the following items: - Accelerate to wide open throttle (WOT). - Release the throttle when fuel cut-off occurs. - Observe the fuel cut-off for the engine that you are performing the learn procedure on. - The engine should not accelerate beyond calibrated RPM value. - Release the throttle immediately if value is exceeded. - Block the drive wheels. - Set the parking brake. - DO NOT apply the brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn the A/C OFF. - The vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. With the scan tool, enable the crankshaft position system variation learn procedure. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release the throttle when the fuel cut-off occurs. 8. The scan tool displays Learn Status-Learned this ignition: - If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. - If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. - If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The crankshaft position system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P1336 sets: Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - Crankshaft position sensor replacement - Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Page 4242 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 2780 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 3746 Steps 1-3 Page 8811 Ambient Temperature Sensor / Switch HVAC: Service and Repair Intake Air Temperature Sensor Lower Left AIR TEMPERATURE SENSOR REPLACEMENT - LOWER LEFT REMOVAL PROCEDURE 1. Remove the IP assembly. 2. Disconnect the electrical connector from the air temperature sensor-lower left (2). 3. Remove the air temperature sensor-lower left. INSTALLATION PROCEDURE 1. Install the air temperature sensor-lower left (2). 2. Connect the electrical connector to the air temperature sensor-lower left. 3. Install the IP assembly. Lower Right AIR TEMPERATURE SENSOR REPLACEMENT - LOWER RIGHT REMOVAL PROCEDURE 1. Remove the passenger side closeout panel. 2. Remove the IP lower closeout panel. Page 1336 Door Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the rear door ajar switches in the door lock assemblies as one method to activate the alarm. The body control module (BCM) monitors rear door ajar switches via a discrete input from each rear passenger door ajar switch, if the BCM receives a ground signal from a rear passenger door ajar switch when the CTD system is armed, the BCM activates the alarm. The CTD system uses the LH front door ajar switch as one method to activate the alarm. The driver door module (DDM) monitors the LH door ajar switch via a discreet input from the door ajar switch, if the DDM receives a ground signal from the LH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the RH front door ajar switch as one method to activate the alarm. The passenger door module (PDM) monitors the RH door ajar switch via a discreet input from the door ajar switch, if the PDM receives a ground signal from the RH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the rear compartment liftgate/liftglass ajar switchs as one method to activate the alarm. The liftgate module (LGM) monitors the liftgate and liftglass ajar switch via a discreet input from the ajar switch, if the LGM receives a ground signal from the liftgate or liftglass ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. Page 1898 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 12363 Memory Seat Module - Passenger C3 Part 1 Page 12005 Paint: Vehicle Damage Warnings Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Page 3896 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 10440 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 4571 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Page 11869 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Page 8219 Air Door Actuator / Motor: Diagrams HVAC System - Manual Air Temperature Actuator - Auxiliary (Body Type VIN 6) Page 9649 Page 13686 Auxiliary Evaporator Block Evaporator Core: Service and Repair Auxiliary Evaporator Block EVAPORATOR BLOCK REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the HVAC module-auxiliary. See: Housing Assembly HVAC/Service and Repair 2. Remove the torx studs from the evaporator block-auxiliary. 3. Remove the evaporator block-auxiliary (1) from the HVAC module-auxiliary. INSTALLATION PROCEDURE 1. Install the evaporator block-auxiliary (1) to the HVAC module-auxiliary. 2. Install the torx studs to the evaporator block-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the studs to 14 N.m (124 lb in). 3. Install the HVAC module-auxiliary. Page 13702 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the pushrod retainer (3) from the brake pedal pin (4). 2. Remove the stop lamp switch (1) and the pushrod (2) from the brake pedal pin (4). 3. Disconnect the stoplamp switch (1) electrical connector. 4. Remove the stoplamp switch from the vehicle. INSTALLATION PROCEDURE 1. Install the electrical connector to the stop lamp switch (1). 2. Position the stop lamp switch (1) on the pushrod (2) and install the assembly on the brake pedal pin. 3. Install the pushrod retainer (3) to the brake pedal pin (4). The retainer will snap into place. Page 13107 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 850 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 12019 WA605H/45 - WA711J/58 Page 3877 Page 947 Powertrain Control Module (PCM) C2 Part 2 Page 9385 Abbreviations And Meanings Part 19 Page 5171 10. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Page 10517 Page 2951 Abbreviations And Meanings Part 23 Page 6769 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 4545 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. 2. Install the APP sensor retaining fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 11622 10. Secure the cylinder in the J 41340. 10.1. Inspect that the spring retainer is facing up and positioned directly under the punch slots. 10.2. Push the cylinder into the J 41340 until butted with the cylinder bezel. 10.3. Tighten the holding screw. 11. Stake the bezel end of the retainer in place: 11.1. Hold the flat side of the punch, part of J 41340, squarely against the face of the cylinder bezel. 11.2. Stake the lock cylinder metal over the retainer corners. Page 8075 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 1186 1. Install sensor into the hub and bearing assembly (6). ^ Tighten the sensor mounting screw (5) to 18 Nm (13 ft. lbs.). Important: The new sensor has new mounting clips already installed on the wire. DO NOT reuse the old clips. 2. Connect the wheel speed sensor electrical connector (2). 3. Install wheel speed sensor mounting clip to the frame rail. 4. Install the wheel speed sensor mounting clip to the control arm. 5. Install the hub and rotor. 6. Install brake caliper. 7. Install tire and wheel. Page 8036 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Page 100 Steps 3-7 Page 12834 Abbreviations And Meanings Part 11 Page 1830 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment The caster and camber adjustments are made by loosening the lower control arm adjustment bolts and repositioning the lower control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. - Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension and the rear suspension D dimension are indicated in Trim Heights. 1. For an accurate reading, do not push or pull on the tires during the alignment process. View Of Left Front Wheel From Left Side Of Vehicle 2. Determine the caster angle. View Of Front Wheel From Front Of Vehicle 3. Determine the camber angle. Page 10419 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Trim Panel Replacement - Knee Bolster Knee Diverter: Service and Repair Trim Panel Replacement - Knee Bolster TRIM PANEL REPLACEMENT - KNEE BOLSTER REMOVAL PROCEDURE 1. Remove the left closeout/insulator panel. 2. Remove the 4 trim panel retaining screws. 3. Release the clips that retain the trim panel to the IP. 4. Remove the trim panel from the IP. INSTALLATION PROCEDURE 1. Position the trim panel to the IP. 2. Seat the clips that retain the trim panel to the IP. 3. Install the 4 trim panel retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.5 N.m (22 lb in). 4. Install the left closeout/insulator panel. Description and Operation Malfunction Lamp / Indicator: Description and Operation AIR BAG INDICATOR The AIR BAG indicator, located in the IPC is used to notify the driver of SIR system malfunctions and to verify that the SDM is communicating with the IPC. When the ignition is turned ON, the SDM is supplied with ignition positive voltage. The SDM requests the IPC to flash the AIR BAG indicator seven times. While flashing the indicator, the SDM conducts test on all SIR system components and circuits. If no malfunctions are detected the SDM will communicate with the IPC through the class 2 serial data circuit and command the AIR BAG indicator OFF. The SDM provides continuous monitoring of the air bag circuits by conducting a sequence of checks. If a malfunction is detected the SDM will store a Diagnostic Trouble Code (DTC) and command the IPC to turn the AIR BAG indicator ON via class 2 serial data. The presence of a SIR system malfunction could result in non-deployment of the air bags or deployment in conditions less severe than intended. The AIR BAG indicator will remain ON until the malfunction has been repaired. Ambient Air Temperature Sensor Replacement Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the front grille. 2. Remove the sensor (1) from the panel assembly (2). 3. Disconnect the electrical connector from the sensor (1). INSTALLATION PROCEDURE 1. Position the sensor to the panel assembly. 2. Connect the electrical connector to the sensor (1). Page 9998 Diagnostic Tips Review Table Page 10038 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 2730 NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the oil filter adapter. Tighten the oil filter adapter to 30 Nm (22 ft. lbs.). 3. Install the oil filter. Page 6176 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 522 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 13628 Headlamp Switch: Diagrams Headlamp Switch C1 Part 1 Page 10745 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9815 Abbreviations And Meanings Part 7 Page 3148 1. Install a new water pump gasket. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the water pump and secure the water pump with the bolts. Tighten ^ On the initial pass, tighten the bolts to 4 Nm (35 lb in). ^ On the final pass, tighten the bolts to 10 Nm (89 lb in). 3. Install the water pump pulley. 4. Install the water pump pulley bolts. 5. Using the J 41240, secure the water pump pulley while tightening the water pump pulley bolts. Tighten Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41240. 7. Install the drive belt. 8. Install the fan and the shroud. 9. Fill the cooling system with the specified coolant and concentration. 10. Inspect for leaks. Page 12642 Heated Seat Element And Thermistor Assembly - Front Passenger Back Page 9417 Page 12109 Page 479 Page 405 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 3091 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Page 10909 Door Control Module Diagram 3 Page 13519 Courtesy Lamp: Description and Operation COURTESY LAMPS The courtesy lamps include the reading lamps, cargo lamp, and dome lamps. The cargo lamp and dome lamps may be manually turned on or off by placing the interior lamp switch in the ON or OFF position. When the driver places the dome lamp defeat switch in the OFF position, these courtesy lamps will be disabled. If a door is opened, the courtesy lamps illuminate. After all the doors have been closed, the courtesy lamps will remain illuminated approximately 15 seconds after the last door closes. The courtesy lamps will also turn on prior to any door being opened and will remain illuminated approximately 40 seconds when the driver removes the ignition key. The BCM will immediately turn off the courtesy lamps if a door lock command is received with all of the doors closed, or if the ignition switch is turned to either the ON or RUN position. Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. A/C - Stops Blowing Cold Air/Cycles ON and OFF Refrigerant: Customer Interest A/C - Stops Blowing Cold Air/Cycles ON and OFF File In Section: 01 - HVAC Bulletin No.: 02-01-39-006A Date: May, 2003 INFORMATION Subject: Diagnosing Poor A/C Performance - A/C Stops Blowing Cold, A/C Cycles On and Off Models: 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL with Automatic or Manual HVAC Auxiliary Temperature Control (RPOs CJ2 or CJ3) This bulletin is being revised to include the underhood label part number. Please discard Corporate Bulletin Number 02-01-39-006 (Section 01 - HVAC). Some of the above listed vehicles may exhibit poor A/C performance due to an overcharged system. If the A/C system is overcharged, it may cause the A/C to stop blowing cold after extended idle or while driving in slow traffic at high ambient temperatures. It has been found that the underhood label containing the A/C charge specification is incorrect. The correct specification should read System Charge with Front and Rear -1.20 kg (2.65 lbs) Use this new charge specification whenever the A/C system is serviced. Install new label, P/N 15103173. Parts Information Parts are currently available from GMSPO. Disclaimer Page 12189 Door Module: Connector Views Driver Door Module (DDM) - C1 Locations Passenger Seat Lumbar Actuators, Driver Seat Similar Page 10828 Page 6992 Application Table Part 1 Page 12495 Page 10065 Parts Information Page 1553 9. Position the headlamp wire harness (1) to the retaining clip. 10. Install and secure the headlamp wire harness in the retaining clip (1). 11. Install the grille. 12. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 5144 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 11841 Abbreviations And Meanings Part 26 Page 12057 WA5322/33 - WA534F/54 Page 4257 Conversion - English/Metric Part 1 Page 13890 Page 4769 Accelerator Pedal Position (APP) Sensor Page 71 Abbreviations And Meanings Part 16 Page 10159 Diagnostic Tips Review # 3 - Denso Navigation Radios Page 3951 Body Control Module (BCM) C1 Part 3 Page 10350 Abbreviations And Meanings Part 3 Page 6308 Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Caution: Refer to Brake Dust Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Weatherstrip Run Channel Assembly Replacement - Front Removal Procedure 1. Remove the door trim panel. 2. Remove the speaker. 3. Remove the water deflector. 4. Remove the window. 5. Remove the 2 bolts that retain the weatherstrip/run channel to the door. 6. Pull the weatherstrip/run channel away from the window frame opening. 7. Carefully twist and pull up on the weatherstrip/run channel, in order remove the weatherstrip/run channel from the top of the door frame. 8. Remove the weatherstrip/run channel from the door. Installation Procedure 1. Install the weatherstrip/run channel to the door. 2. Position the tabs on the weatherstrip/run channel into the slots in the door. 3. Press the weatherstrip/run channel into the window frame opening. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 retaining bolts. Tighten the retaining bolts to 10 N.m (88 lb in). 5. Install the window. 6. Install the water deflector. 7. Install the speaker. 8. Install the door trim panel. Page 3923 Abbreviations And Meanings Part 10 Page 13973 Steps 1-4 Page 5135 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Slde Page 6850 Page 8121 Disclaimer Page 6431 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation. Parts should be ordered on a CSO Customer Special Order. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Ask for Item Number GMP 91 when ordering. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Page 6045 Disclaimer Page 7978 Install the shock module to the shock tower and lower control arm. Install the shock module yoke to the lower control arm. Lower the vehicle. Refer to Fastener Notice. Install the shock module upper retaining nuts. Tighten Tighten the shock module upper retaining nuts to 45 N.m (33 lb ft). Raise the vehicle. Install the shock module yoke to lower control arm retaining nut. Page 5815 4. Install the selective shim between the inner pinion bearing and the shoulder on the gear. 5. Install the inner pinion bearing using the J24433. Press the bearing on until the cone seats on the pinion shim. 6. Install a new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 8. Install the pinion into the axle housing., 9. Install the outer pinion bearing onto the pinion. 10. Install a new pinion oil seal using the J33782, 8.0 inch axle, or the J38694, 8.6 inch axle. 11. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. 12. Install the pinion yoke. Align the marks made during removal. 13. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 14. Install the washer and a new pinion nut. Page 1751 Abbreviations And Meanings Part 15 Page 895 Body Control Module (BCM) C3 Part 2 Page 2902 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 12448 2. Install the seat cover J-strips (1) to the seat cushion trim panel (2). 3. Install the two bolts (2) securing the support (1) to the seat cushion trim panel. Tighten Tighten the rear seat support bolts to 35 N.m (26 lb ft). 4. Install the rear seat bracket with the four mounting nuts (2). Page 10417 Testing and Inspection Oil Level Warning Indicator: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 4141 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 12162 Abbreviations And Meanings Part 7 Page 6404 Amplifier Replacement 1 Amplifier: Service and Repair Amplifier Replacement 1 AMPLIFIER REPLACEMENT (BRAVADA, ENVOY, TRAILBLAZER) REMOVAL PROCEDURE 1. Remove the upper right quarter trim panel. 2. Remove the lower right quarter trim panel. 3. Disconnect the electrical connectors from the radio speaker amplifier. 4. Remove the 4 bolts that retain the radio speaker amplifier to the body. 5. Remove the radio speaker amplifier from the body. INSTALLATION PROCEDURE 1. Install the radio speaker amplifier to the body. 2. Install the 4 bolts that retain the radio speaker amplifier to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (88 lb in). 3. Connect the electrical connectors to the radio speaker amplifier. 4. Install the lower right quarter trim panel. 5. Install the upper right quarter trim panel. Keyless Entry - System Inoperative Door Module: Customer Interest Keyless Entry - System Inoperative Bulletin No.: 03-08-52-002 Date: March 27, 2003 TECHNICAL Subject: Remote Keyless Entry Inoperative (Reprogram Liftgate Module) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the Remote Keyless Entry (RKE) is inoperative at times. Cause An anomaly has been identified with the software in the Liftgate Module (RKE functions). The Liftgate Module software is affected when the temperature is approximately 40°C (104°F). Correction Using normal SPS reprogramming procedures, reprogram the LGM Liftgate module. The information was released on TIS version 2.75 or newer broadcast in March 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8431 Blower Motor Switch: Service and Repair HVAC System - Automatic FRONT AUXILIARY BLOWER MOTOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Press downward and to the right on the front auxiliary blower motor switch. 2. Remove the front auxiliary blower motor switch from the console. 3. Disconnect the electrical connector from the front auxiliary blower motor switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the front auxiliary blower motor switch. 2. Install the front auxiliary blower motor switch to console. 3. Press the front auxiliary blower motor switch into the console. Page 7045 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 5487 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Page 9178 Abbreviations And Meanings Part 11 Page 6762 Page 4910 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 13165 For the list of Driver Warnings, refer to Indicator/Warning Message Description and Operation. Page 12755 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Rear Door Window Belt Inner Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Inner Removal Procedure 1. Open the door. 2. Remove the door trim panel. 3. Starting at the back of the strip, carefully lift the strip off the pinch-weld flange until the strip is completely released. Installation Procedure 1. Install the sealing strip to the pinch-weld flange. Ensure that the strip is fully seated. 2. Install the door trim panel. 3. Close the door. Rear Door Window Belt Outer Sealing Strip Replacement Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure 1. Remove the screw that retains the sealing strip to the door. 2. Lift upward on the forward edge of the sealing strip. 3. Remove the sealing strip from the pinch-weld flange. Installation Procedure Engine Controls - SES Lamp ON/DTC's P0133/P0172 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - SES Lamp ON/DTC's P0133/P0172 Bulletin No.: 04-06-04-053 Date: July 20, 2004 TECHNICAL Subject: Service Engine Soon Light On, P0133, P0172 (Reprogram PCM) Models: 2004 Buick Rainier 2003-2004 Chevrolet Trailblazer 2003-2004 GMC Envoy 2003-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on the Service Engine Soon light coming on and no apparent vehicle driveability condition. Upon investigation, the technician will find diagnostic trouble codes P0133 or P0172. Correction Reprogram the PCM with the latest calibration available. The new calibration will be released beginning with TIS satellite data update version 2.5 for 2004 available February 2004. As always, make sure your TECH2(R) is updated with the latest software version. Warranty Information For vehicles repaired under the applicable 8 year or 80,000 mile (130,000 kilometers) emission controller warranty, use the table. Disclaimer Page 634 Door Module: Electrical Diagrams Door Control Module Diagram 1 Page 1346 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Open the left instrument panel (IP) access cover. 2. Reach into the access hole and release the 4 retaining tabs located on the headlamp switch behind the IP. 3. Remove the headlamp switch from the IP, through the IP access hole. 4. Disconnect the electrical connectors from the headlamp switch. 5. Remove the headlamp from the IP. INSTALLATION PROCEDURE Page 12073 WA8555/41 - WA8555/41 Page 793 7. Remove the junction block bracket retaining bolts (1) and remove the junction block bracket from the vehicle. INSTALLATION PROCEDURE 1. Position the junction block bracket and install the bolts (1). Tighten Tighten the junction block bracket bolts to 6 N.m (53 lb in). 2. Align the wiring harnesses and install the fuse relay center. 3. Install the fuse relay center bolts (3). Tighten Tighten the relay center bolts to 6 N.m (53 lb in). Page 7179 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 12836 Abbreviations And Meanings Part 13 Page 3097 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 4167 TEST DESCRIPTION Step 1 Page 8308 40.1. Install the ring terminal (black wire) to ground G103 (1), located on the right side inner tender. 40.2. Route the pump wiring harness along the existing right side forward lamp harness. 40.3. Connect the electrical connectors to the coolant bypass valve (1) and auxiliary heater pump (2). 40.4. Position the relays onto the inner wheelhouse panel near the rear of the engine compartment. Heated Oxygen Sensor (HO2S) 1 Replacement Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 1 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). 2. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must install the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. 2. Install the heated oxygen sensor (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Page 2182 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module yellow 4-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 1. Remove the key from the ignition. Page 238 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 8943 Inflatable Restraint Side Impact Sensor-Right (SISM) Locations Engine Page 7330 Fuse Block - Rear C1 Part 4 Page 8173 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 8160 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 11044 12. Install and hand tighten the two remaining bolts. 13. Align the hinge to the original scribe location and torque all of the four bolts to 25 N.m (18 lb ft). 14. Clean and prepare all bare-metal surfaces. 15. Apply a full-bodied caulk around the service hinge (1). 16. Refinish as necessary. 17. Install and align all of the related panels and components. Page 7263 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 2472 Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. Page 12518 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 13726 Headlamp Switch: Diagrams Headlamp Switch C1 Part 1 Page 11487 Install a new license plate pocket perimeter gasket onto the backside edge of the pocket housing as shown above, starting at the middle of the seal at the top center of the pocket. This will ensure that the seal will be even. When properly installed, there will be 25-50 mm (1-2 in) on either side of the liftgate release handle (2) that the seal (1) does not reach. DO NOT attempt to install the seal on the liftgate directly below the release handle. Install the license plate pocket assembly onto the liftgate. Refer to the License Plate Pocket Replacement procedure in the Body Rear End (2006 MY and prior) or Exterior Trim sub-section of SI. Modify the tightening sequence for the screws that retain the pocket assembly to the liftgate as follows: Push the entire rear license plate pocket assembly upward in the opening of the liftgate. Inspect the perimeter gasket to see if it is properly retained. Tighten Tighten the rear license plate pocket assembly retaining nuts to 5 N.m (44 lb in) in the following order. Tighten the upper left retaining nut first. Tighten the upper right retaining nut second. Tighten the three lower retaining nuts in any order. Parts Information Rear No. 1 Child Seat Tether Attachment: Service and Repair Rear No. 1 REMOVAL PROCEDURE 1. Open the liftgate. 2. Remove the bolt that retains the child restraint tether anchor to the floor panel. 3. Remove the child restraint tether anchor from the floor panel. INSTALLATION PROCEDURE 1. Install the child restraint tether anchor to the floor with the pivot point of the anchor ring indexed toward the front of the vehicle. 2. Install the bolt that retains the child restraint tether anchor to the floor panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the child restraint tether anchor bolt to 35 N.m (26 lb ft). 3. Close the liftgate. Page 898 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Page 9373 Abbreviations And Meanings Part 7 Page 12849 Abbreviations And Meanings Part 26 Page 4251 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 12166 Abbreviations And Meanings Part 11 Page 1709 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 12514 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 8492 Instrument Panel, Center (w/Automatic - HVAC System) Page 9205 Steps 4-6 The numbers below refer to the step numbers on the diagnostic table. 1. This step verifies that the RAP power mode function is malfunctioning by checking functions internally enabled by the BCM. 4. The BCM sends Class 2 messages to other control modules via the serial data link, allowing them to operate in RAP power mode. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 5. This step is checking for DTCs in the BCM. 6. The presence of DTCs which begin with "U" indicate that other module is not communicating. The specified procedure will compile all the available information before tests are performed. Page 309 Disclaimer Page 10684 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Service and Repair Front Door Limiter: Service and Repair Door Check Link Replacement Removal Procedure 1. Remove the door trim panel. 2. Remove the front half of the water deflector in order to expose the door access hole. 3. Remove the 2 bolts that retain the check link to the pillar. 4. Remove the rubber dust boot from the check link in order to gain access to the door retaining nuts. 5. Remove the 2 check link retaining nuts from the door. 6. Remove the check link assembly through the door access hole. Installation Procedure Page 2979 14. Remove the valve spring retainer and the valve 15. Use the J 38320 and remove the seals. 16. Clean and inspect the cylinder head. Installation Procedure Important: Lubricate the valve stems with clean engine oil before installing. 1. Use the J 33820 to install the valve seals. There is only one size seal. Page 13090 Page 8435 Instrument Panel Carrier-Air Duct B-Pillar, Left Page 2982 12. Install the spark plugs. 13. Install the camshaft cover. Page 4643 Fuel Pressure Regulator: Service and Repair REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the air cleaner outlet resonator. 3. Disconnect the engine wiring harness from the retaining clips at the front of the engine. 4. Disconnect the fuel pressure regulator vacuum line. 5. Clean any dirt from the fuel pressure regulator and the surrounding area. 6. Disconnect the fuel return pipe. 7. Remove the fuel return pipe retainer. 8. Remove the fuel pressure regulator retainer. 9. Remove the fuel pressure regulator. 10. Inspect the regulator filter screen for contamination. If contaminated, replace the fuel pressure regulator. INSTALLATION PROCEDURE 1. Install the regulator filter. 2. Install the new O-ring on the fuel pressure regulator. 3. Lubricate the fuel pressure regulator O-ring with clean engine oil. 4. Push the fuel pressure regulator into the regulator housing on the fuel rail. 5. Install the fuel pressure regulator retainer. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the regulator retainer screw to 8 N.m (71 lb in). Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 10683 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 8875 Ambient Light/Sunload Sensor Assembly Page 3836 Spark Plug: Testing and Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 9831 Abbreviations And Meanings Part 23 Page 12515 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 10001 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Page 12513 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 10695 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 13235 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 4845 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 6378 5. Release the wiring harness from the retaining clips (2) on the frame and reposition the harness as necessary to allow for removal of the brake pipe. 6. Disconnect the wheel speed sensor harness connector (1) located on the outboard side of the left frame rail near the front caliper brake hose fitting. 7. From the left front wheelhouse, remove the brake pipe from the vehicle. 8. Position the new brake pipe to the vehicle and install it in the retainers on the frame. Notice To avoid damaging the threads on the ABS modulator, flare nuts, or the front brake hose fitting, use only your fingers to start the threads. Do not use tools to start threading the flare nut into the ABS modulator or the front brake hose fitting. 9. Connect the brake pipe to the ABS modulator and tighten the flare nut. Tighten to 20 N.m (15 lb ft). 10. Connect the brake pipe to the left front caliper brake hose fitting. Tighten lighten the flare nut to 20 N.m (15 lb ft). 11. Position the wiring harness to the frame and secure in the retainers. 12. Connect the wheel speed sensor harness connector. Important Do not drive the vehicle until the brake pedal feels firm. Do not reuse brake fluid that is used during bleeding. 13. Lower the vehicle as necessary to allow for manual bleeding of the left front brake assembly. Caution Refer to Brake Fluid Caution in the Cautions and Notices in the appropriate Service Manual. Notice Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices in the appropriate Service Manual. Notice When adding fluid to the brake master cylinder reservoir, use only DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination, which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Important Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm in the next step. 14. Fill the brake master cylinder reservoir with Delco Supreme 11(R), GM P/N 12377967, Canadian P/N 89021320, or equivalent DOT-3 brake fluid from a clean sealed brake fluid container. 15. Install the J 35589-A to the brake master cylinder reservoir. 16. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme 11(R) or equivalent DOT-3 brake fluid from a clean sealed brake fluid container as necessary to bring the level to approximately the half-full point. 17. Connect the J 29532, or equivalent, to the J 35589-A. 18. Charge the J 29532, or equivalent, air tank to 175-205 kPa (25-30 psi). 19. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 3937 Abbreviations And Meanings Part 24 Page 11208 Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. Page 12080 WA9260/74 - WA9539/47 Page 1674 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 13567 1. Remove the 2 screws that retain the insulator panel to the instrument panel (I/P). 2. Release the insulator panel retaining clip from the I/P substrate. 3. Lower the insulator panel. 4. Remove the flasher retaining bracket from the insulator panel. 5. Disconnect the flasher from the electrical connector. 6. Remove the flasher from the vehicle. 7. Position the new flasher to the insulator panel. 8. Connect the electrical connector to the flasher. 9. Install the flasher retaining bracket to the insulator panel. 10. Install the insulator panel tabs to the cowl slots. 11. Raise the insulator panel to the I/P. 12. Install the insulator panel retaining clip to the I/P substrate. 13. Install the 2 screws that retain the insulator panel to the I/P. Tighten Tighten the screws to 2.5 N.m (22 lb in). Page 5231 For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 70 Abbreviations And Meanings Part 15 Recall - Spark Plug Misfire Condition Spark Plug: All Technical Service Bulletins Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Page 9985 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Diagrams Oil Level Sensor For ECM: Diagrams Engine Oil Level and Temperature Sensor Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Page 2267 4. Install the harness end bolts (2). 5. Install the fuse relay center cover (1) over the relay center bolts. Press downward to engage the tabs. 6. Install the junction block cover. Press downward to engage the tabs. Page 13243 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 13077 Driver/Vehicle Information Display: Locations Steering Wheel Controls Page 3043 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Page 13532 Lifgate Ajar Switch Page 472 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 4978 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 8220 Air Temperature Actuator - Left Locations Park Neutral Position (PNP) Switch Page 12978 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Locations Electronic Components Page 12870 Brake Rotor Replacement Brake Rotor/Disc: Service and Repair Brake Rotor Replacement Front The content of this article reflects the changes identified in TSB 03-05-23-002A Brake Rotor Replacement - Front Removal Procedure ^ Tools Required J 42450-A Wheel Hub Cleaning Kit 1. Inspect the brake fluid level in the brake master cylinder reservoir. 2. If the brake fluid is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, using a appropriate tool, remove the brake fluid to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. Page 9156 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 7457 C101 Part 1 Page 4074 Page 3902 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 3599 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 5186 Page 4359 Powertrain Control Module (PCM) C2 Part 3 Page 13068 Door Switch: Diagrams Miniwedge (Door Jamb Switch) - LF Page 6159 Page 5664 4. Remove the transmission jack. 5. Install the nuts securing the transmission mount to the transmission support. ^ Tighten the nuts to 46 Nm (35 ft. lbs.). 6. Lower the vehicle. Recall - Brake Pipe Scoring Technical Service Bulletin # 03025 Date: 030501 Recall - Brake Pipe Scoring File In Section: Product Recalls Bulletin No.: 03025 Date: May, 2003 PRODUCT SAFETY RECALL SUBJECT: 03025 - BRAKE PIPE SCORING MODELS: 2003 CHEVROLET TRAILBLAZER 2003 GMC ENVOY 2003 OLDSMOBILE BRAVADA CONDITION General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2003 model year Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles. On some of these vehicles, the front left brake pipe may have been scored during manufacturing. The brake pipe may lose strength at the score location due to corrosion and fatigue resulting from brake fluid pressure, vibration, and temperature changes. As a result of this, the brake pipe may eventually fracture at the score location. If the brake pipe were to fracture, brake pedal travel would be increased and front brake performance would be reduced. In these instances, braking would be limited to that available with the remaining half system (rear brakes). In all of the above cases, the brake light would illuminate after sufficient fluid leaked out of the system to activate the low fluid level switch in the master cylinder reservoir. These conditions would meet the half system requirements of MVSS 135. CORRECTION Dealers are to inspect the front left brake pipe and replace it, if necessary. VEHICLES INVOLVED Involved are certain 2003 Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 12812 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 9626 Page 6924 7. Using your finger, remove the socket retaining ring by pulling the retaining ring out of the mounting hole. INSTALLATION PROCEDURE 1. Position the retaining ring to the mounting hole. 2. Index the key to the retaining ring to the slot in the mounting hole. 3. Install the retaining ring by pressing the retaining ring into the mounting hole until fully seated. 4. Connect the electrical connector to the socket. 5. Position the socket to the retaining ring. 6. Install the socket into the retaining ring by pressing in the socket until fully seated. 7. Install the 12 volt power supply or cigar lighter fuse. Page 2303 The rear end lift points for the floor jack are at the following locations: - Beneath the axle housing, inboard from the shock absorber mounts - Beneath the axle differential Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: - Chock the wheels at the end of the vehicle opposite the end being lifted - Use jack stands for support. Place jack stands at the any of the following locations: - Beneath the frame - Beneath the front suspension crossmember - Beneath the axle When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. NOTE: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: - The catalytic converter - The brake lines - The brake cables - The fuel lines - The accelerator cables - The transmission shift cables Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Service and Repair Blower Motor Relay: Service and Repair BLOWER MOTOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover of the under hood fuse block. 2. Remove the blower motor relay (1) from the under hood fuse block (2). INSTALLATION PROCEDURE 1. Install the blower motor relay (1) to the under hood fuse block. 2. Install the cover of the under hood fuse block. Page 3494 Abbreviations And Meanings Part 11 Page 1472 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Page 2937 Abbreviations And Meanings Part 9 Steering - Steering Column Squeaking/Rubbing Noise Steering Shaft: All Technical Service Bulletins Steering - Steering Column Squeaking/Rubbing Noise Bulletin No.: 02-02-35-006B Date: March 17, 2006 TECHNICAL Subject: Squeak, Rub/Scrub Type Noise in Steering Column (Lubricate Upper Intermediate Shaft Serration (Slip) Joint and Remove Material from Upper Intermediate Shaft Bushing) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to change the lubricant part number. Please discard Corporate Bulletin Number 02-02-35-006A (Section 02 - Steering). Condition Some customers may comment on a squeak noise coming from the steering column while turning the steering wheel. Some customers may also comment on a rubbing/scrubbing type noise/feel in the steering wheel during low speed turns/parking maneuvers. This condition may be more pronounced in cold temperatures. The rubbing/scrubbing noise condition affects vehicles built prior to VIN breakpoint 32214010 (Moraine, OH) and 36170447 (Oklahoma City, OK). Cause Inadequate distribution and amount of grease in the serration (slip) joint of the upper intermediate shaft may cause the squeak noise. The rubbing/scrubbing type noise may be due to an interference fit between the upper intermediate shaft boot seal and the intermediate shaft bushing. Correction Lubricate the upper intermediate shaft serration (slip) joint. After lubrication, remove material from the upper intermediate shaft bushing. Use the following procedure. 1. Remove the two screws that retain the left closeout/insulator panel to the instrument panel (IP). 2. Release the insulator panel retaining clip from the IP substrate and lower the panel. 3. Remove the push pin retainer and the LH floor air outlet duct from the heater module. 4. Insert the flexible applicator hose of the spray lubricant, P/N 89021668 (Canadian P/N 89021674), through the top, hollow end (1) of the intermediate shaft. Page 1974 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Install 3/3 inch breaker bar on the drive belt tensioner arm and turn the breaker bar clockwise enough to relieve the tension on the drivebelt. 2. Remove the drivebelt. 3. Release the tension on the tensioner arm. Installation Procedure 1. Route the drivebelt over all the pulleys except the drivebelt tensioner pulley. 2. Install the 3/8 inch breaker bar on the drivebelt tensioner arm and turn the breaker bar clockwise. 3. Install the drivebelt over the drivebelt tensioner pulley. 4. Slowly release the tension to the drivebelt tensioner arm. 5. Inspect for proper installation of the drivebelt on the pulleys. Page 7739 1. Apply grease provided to inside of rack and pinion boot ribs (4). 2. Place the new large seal retaining clamp (3) onto rack and pinion boot (4). 3. Install boot (4) over inner tie rod end. Align the arrows (2) on boot (4) with the range (1) marked on the gear housing. 4. Install the new small seal retaining clamp (2) over the boot (1). 5. Slide the boot (1) towards the center of the gear assembly until the boot seats in the inner tie rod retaining groove. Page 5302 If water or coolant is found in the transmission, the following components MUST be replaced. ^ Replace all of the rubber type seals. ^ Replace all of the composition4aced clutch plate assemblies including the band. ^ Replace all of the nylon parts (Thrust Washers). ^ Replace the torque converter. ^ Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. ^ Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052C or newer - Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator WITH the transmission REMOVED from vehicle. 1. Remove the transmission fluid filler tube from the transmission. 2. Replace the transmission fill tube seal, P/N 1259475. 3. Replace the transmission fill tube, P/N 15000220, following the appropriate SI Document for Transmission Installation. 4. Replace the transmission fluid level indicator, P/N 15069769 when appropriate during the transmission installation. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator with the transmission in the vehicle. 1. Remove the air cleaner outlet duct. 2. Remove the transmission fluid level indicator from the filler tube. 3. Remove the filler tube nut (2) located on the right side of the engine. 4. Remove the filler tube from the vehicle. Page 606 Abbreviations And Meanings Part 18 Page 1272 A/C Low Pressure Switch (w/Automatic - HVAC System) Page 12798 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 8758 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the A/C low pressure switch electrical connector. 2. Remove the A/C low pressure switch (2) from the accumulator (1). 3. Remove and discard the O-ring seal from the A/C low pressure switch port on the accumulator. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the A/C low pressure switch (2) to the accumulator (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the A/C low pressure switch to 4.8 N.m (42 lb in). 3. Connect the A/C low pressure switch electrical connector. 4. Leak test the fittings of the components using the J 39400-A. Page 4303 Body Control Module (BCM) C1 Part 2 Page 10915 10. With an upward motion, remove the BCM (1) from the rear electrical center. INSTALLATION PROCEDURE 1. Index the slots on the BCM (1) to the rear electrical center. 2. Using a downward motion, install the BCM to the rear electrical center. Page 10071 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 5816 15. Install the J8614-01 onto the pinion yoke as shown. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 16. Tighten the pinion nut while holding the J8614-01. Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 17. Measure the rotating torque of the pinion using an inch-pound torque wrench. Specification The rotating torque of the pinion should be 1.0 - 2.8 Nm (10 - 25 inch lbs.) for used bearings, or 1.7 - 3.4 Nm (15 - 30 inch lbs.) for new bearings. 18. If the rotating torque measurement is below 1.0 Nm (10 inch lbs.) for used bearings, or 1.7 Nm (15 inch lbs.) for new bearings, continue to tighten the pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.0 - 2.8 Nm (10 - 25 inch lbs.) for used bearings, or 1.7 3.4 Nm (15 - 30 inch lbs.) for new bearings. 19. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 20. Install the differential. 21. Install the brake rotors. 22. Install the brake calipers. 23. Install the tire and wheel assemblies. 24. Fill the axle with axle lubricant lubricant. Use the proper fluid. 25. Lower the vehicle. Page 1708 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 2065 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Page 12519 5. Tape over the entire cable. Use a winding motion when you apply the tape. Procedures Sun Visor: Procedures SUNSHADE REPLACEMENT REMOVAL PROCEDURE 1. Remove the windshield garnish molding. 2. Release the front assist handle from the headliner. 3. Recline the bucket seat and release the upper portion of the center pillar trim panel. Refer to Garnish Molding Replacement - Center Pillar. 4. Open and rotate the sunshade parallel to the side window. 5. Insert a small tool into the bezel access hole (1). 6. Push upward on the tool while rotating the sunshade parallel to the windshield. The sunshade pivot arm bezel should appear to be recessed into the bezel. IMPORTANT: Midway through the rotation cycle, the tool will move further into the access hole. 7. Apply outboard pressure to the sunshade while the sunshade is parallel to the windshield. IMPORTANT: Ensure the pivot arm is recessed into the bezel before removing the sunshade from the headliner. Page 11417 Trunk / Liftgate Motor: Service and Repair ACTUATOR REPLACEMENT - REAR QUARTER WINDOW REMOVAL PROCEDURE 1. Remove the rear interior trim panel covering the actuator. 2. Disconnect the electrical connection (1). 3. Remove the actuator arm (1) to the window hinge screw (2) 4. Remove the actuator retaining nuts. 5. Remove the actuator from the vehicle. Locations Sunroof / Moonroof Module: Locations Roof With Headliner Removed Page 7955 Tighten the clamps to 2.5 N.m (22 lb in). 17. Lower the vehicle. 18. Install the fuel fill pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the fuel fill pipe housing. 20. Install the fuel fill cap. Parts Information Parts are expected to be available from GMSPO on August 13, 2004. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 3970 6. Install the rear electrical center cover. 7. If replacing the body wiring harness extension on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 8. If replacing the body wiring harness extension on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 9. Connect the negative battery cable. Camshaft Actuator System Camshaft Position Sensor: Description and Operation Camshaft Actuator System CAMSHAFT POSITION (CMP) ACTUATOR SYSTEM The Camshaft Position Actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation control, a wider engine torque range, improved gas millage, and improved engine idle stability. The CMP Actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. CMP ACTUATOR SYSTEM OPERATION The CMP Actuator system is controlled by the Powertrain Control Module (PCM). The PCM sends a pulse width modulated 12 volt signal to a Camshaft Position (CMP) Actuator Solenoid in order to control the amount of engine oil flow to a cam Phaser passage. There are two different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The Cam Phaser is attached to a camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position. Engine oil pressure, viscosity, temperature and engine oil level can have an adverse affect on cam phaser performance. The PCM calculates the optimum cam position through the following inputs: Engine Speed - Manifold Absolute Pressure (MAP) - Throttle Position (TP) Indicated Angle - Crankshaft Position (CKP) - Camshaft Position (CMP) - Engine Load. - Barometric (BARO) Pressure The Cam Phaser default position is 0 degrees. The PCM uses the following inputs before assuming control of the cam phaser: Engine Coolant Temperature (ECT) - Closed Loop Fuel Control - Engine Oil Temperature - Engine Oil Pressure - Engine Oil Level - CMP Actuator Solenoid circuit state - Ignition 1 signal voltage - Barometric (BARO) Pressure CMP ACTUATOR SOLENOID CIRCUIT DIAGNOSTICS The PCM monitors the control circuits of the CMP Actuator Solenoid for electrical faults. The PCM has the ability to determine if a control circuit is open, shorted high, and shorted low. If the PCM detects a fault with a CMP Actuator Solenoid circuit a Diagnostic Trouble Code (DTC) will set. CMP ACTUATOR SYSTEM PERFORMANCE DIAGNOSTICS The PCM monitors the performance of the CMP Actuator system by monitoring the actual and desired positions of a cam phaser. If the difference between the actual and desired position is more than a calibrated angle for more than a calibrated amount of time, a DTC will set. Page 7078 C101 Part 1 Page 7290 Abbreviations And Meanings Part 26 Page 4788 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE 1. Install the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Page 10275 Speaker - LF I/P (With RPO Code UQA) Page 9360 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 119 Page 5203 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: Customer Interest Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 12303 Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Hose Replacement - Rear SUNROOF DRAIN HOSE REPLACEMENT - REAR REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement (TrailBlazer, Envoy, Bravada)Headliner Replacement (TrailBlazer EXT, Envoy XL) in Interior Trim. 2. Disconnect the rear sunroof drain hose from the sunroof module rear spigot, right or left side, as needed. 3. Remove the hose clip securing the drain hose to the vehicle, right or left side, as needed. 4. Remove the drain hose from the vehicle, right or left side, as needed. INSTALLATION PROCEDURE 1. Route the end of the drain hose through the access hole and down the inner side panel, right or left side, as needed. 2. Install the hose clip to the door frame securing the drain hose to the vehicle, right or left side, as needed. Page 9762 Page 4085 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 859 Abbreviations And Meanings Part 4 Page 12150 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 4815 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 13106 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 7467 C118 Page 4954 Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side Page 12940 Registered And Non-Registered Trademarks Part 3 Inlet Radiator Hose: Service and Repair Inlet Body VIN Code 3 Radiator Hose Replacement - Inlet (Body Vin Code 3 / GMT 360) Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the coolant. 2. Reposition the inlet radiator hose clamp at the thermostat (1) using J 38185. 3. Remove the inlet radiator hose from the thermostat. 4. Raise the vehicle. Refer to Vehicle Lifting. See: Service Precautions/Technician Safety Information/Vehicle Lifting Caution 5. Remove the lower radiator support shield, if equipped. 6. Reposition the inlet radiator hose clamp at the radiator using J 38185. 7. Remove the inlet radiator hose (1) from the radiator. Installation Procedure Page 6018 3. Install the 1-2 and 2-3 Shift solenoids. 4. Install the 1-2 and 2-3 Shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. Page 1602 10. Remove the air spring level sensor to the frame mounting bolts. 11. Remove the air spring level sensor. Installation Procedure 1. Install the air spring level sensor link to the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not remove the air spring level sensor locating pin until the air spring level sensor has been properly aligned and the proper D height has been measured and maintained. 2. Install the air spring level sensor to the frame mounting bolts. Tighten the air spring level sensor to the frame mounting bolts to 8 Nm (6 lb ft). Page 7083 C104 Part 2 C105 Part 1 Page 7944 For vehicles repaired under warranty, use the table. Disclaimer Page 1955 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 7072 For vehicles repaired under warranty, use the table. Disclaimer Locations Front Passenger Seat Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Press tabs (1) inward and lift to remove the junction block cover. 3. Pull upward on the fuse relay center cover (1) to release the retaining tabs and remove the cover. 4. Note the location and remove the harness end bolts (2) and remove the harness ends from the fuse relay center. 5. Remove the fuse relay center bolts (3) and remove the fuse relay center from the junction block bracket. 6. Pull downward on the wiring harness ends to remove from the bottom of the fuse relay center. Page 12984 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Locations Cabin Temperature Sensor / Switch: Locations Instrument Panel Carrier - Right Side Instrument Panel Carrier - Center Section Page 11159 Page 9548 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 7270 Abbreviations And Meanings Part 6 Page 12125 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 8213 Console Mode Actuator (Body Type VIN 6) Page 7004 4. Install the harness end bolts (2). 5. Install the fuse relay center cover (1) over the relay center bolts. Press downward to engage the tabs. 6. Install the junction block cover. Press downward to engage the tabs. Page 462 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 7256 Conversion - English/Metric Part 2 Page 7440 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 3701 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 1423 1. Install the MAP sensor (2). 2. Install the MAP sensor retainer (1). 3. Connect the electrical connector. Page 8906 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 4. Install the RF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 3. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. Page 3905 Conversion - English/Metric Part 2 Page 9913 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 9206 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms - Accessory Delay Module SYMPTOMS - ACCESSORY DELAY MODULE IMPORTANT PRELIMINARY CHECKS BEFORE STARTING 1. Perform the Diagnostic System Check - Accessory Delay Module before using the Symptom Tables in order to verify that all of the following are true: There are no DTCs set. - The control module(s) can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Accessory Delay Module 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory power (RAP) Description and Operation. VISUAL/PHYSICAL INSPECTION - Inspect for aftermarket devices which could affect the operation of the Accessory Delay Module system. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout (with Relay)Retained Accessory Power (RAP) On After Timeout (No Relay, Class 2) - Retained Accessory Power (RAP) Inoperative (with relay)Retained Accessory Power (RAP) Inoperative (No Relay Class 2) Page 9620 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 7203 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 10755 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 602 Abbreviations And Meanings Part 14 Page 3909 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 13728 Headlamp Switch C2 Page 8237 Important: The new actuator is in Bi-Level mode. Place the door in the middle of the travel position before you install the actuator. 1. Install the mode actuator (1). Notice: Refer to Fastener Notice. 2. Install the screws to the mode actuator (1). Tighten the screws to 1.9 Nm (18 inch lbs.). 3. Install the left hand floor duct. 4. Install the left side sound insulator screws. 5. Recalibrate the mode actuator, See: Testing and Inspection/Programming and Relearning Mode Actuator Console MODE ACTUATOR REPLACEMENT - CONSOLE REMOVAL PROCEDURE 1. Remove the console. 2. Remove the screw from the air outlet duct. 3. Remove the air outlet duct from the console. Page 12625 Lumbar Adjuster Switch - Passenger (w/Heat) Page 1603 3. Connect the air spring level sensor electrical connector. Notice: Failure to remove the air suspension auto level control sensor locating pin before the rear axle support is removed will cause damage to the air suspension auto level control sensor. 4. Remove the air spring level sensor locating pin. 5. Remove the rear axle support. 6. Install the rear tire and wheels. 7. Lower the vehicle. 8. Install the air suspension system fuse. 9. Start the vehicle and run for approximately 1 minute to ensure that the air spring leveling system is functioning properly. 10. Check the D height. Page 9766 Page 3412 11. Lower the vehicle. 12. Install the oil level indicator tube. 13. Move the transmission filler tube back onto the A.I.R. adapter block stud and secure the tube with a nut. Tighten the transmission filler tube bracket nut to 10 Nm (89 inch lbs.). 14. Install the air cleaner resonator outlet duct. Page 3995 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. 1. Install the CKP sensor into the engine block. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Service and Repair Tie Rod End: Service and Repair Tie Rod End Replacement - Outer Tools Required ^ J24319-B Steering Linkage and Tie Rod Puller Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the outer tie rod retaining nut. Notice: Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint. Page 12001 For vehicles repaired under warranty use, the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty use, the table. Page 12712 Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 10971 Rear Bumper Cover / Fascia: Service and Repair Fascia Replacement - Rear Bumper Removal Procedure 1. Remove the backup lamp socket assemblies from the backup lamp housings, if applicable. 2. Remove the lower fascia push-pins. 3. Remove the screws from the rear wheelhouse flanges. 4. Remove the upper retaining bolts from the back of the fascia. 5. Remove the fascia from the vehicle. Installation Procedure Page 10651 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 7693 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 4. Install the LF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Locations Engine, Left Front Page 3737 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE 1. Install the knock sensor (1 or 2) and the bolt (3). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 11783 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 6232 Registered And Non-Registered Trademarks Part 5 Page 7224 Page 7119 C401 (Body Type VIN 6) Part 2 Page 4104 Various symbols in order to describe different service operations. Page 3455 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 266 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 3511 Registered And Non-Registered Trademarks Part 2 Page 662 Memory Seat Module - Driver C4 Part 1 Page 10723 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 11199 For 2007 vehicles repaired under warranty, use the table. Disclaimer Locations Power Seat Page 4143 Registered And Non-Registered Trademarks Part 3 Page 6811 Abbreviations And Meanings Part 15 Page 14021 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 14007 Page 10848 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 247 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 251 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 13484 Tighten the two screws to 2.5 N.m (22 lb in). Clean the application area of the CHMSL applique with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984 or equivalent, and dry thoroughly using a clean low lint towel or towelette. Apply double-sided adhesive tape, 3M(R) P/N 06397 or equivalent, to the underside of the CHMSL applique. Remove the old adhesive from the liftgate glass. The installation area of the liftgate glass must be clean and dry. Any airborne dust, oils, etc., may contaminate the glass or the applique adhesive, and reduce the bond of the tape. DO NOT use commercial glass or surface cleaners. These may contain petroleum. The glass surface temperature should be no lower than 21°C (70°F) and not exceed 38°C (100°F). Clean the application area of the liftgate glass with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984 or equivalent, and dry thoroughly using a clean low lint towel or towelette. Apply adhesive promoter, P/N 12378555 (in Canada, use P/N 88901239), to the liftgate glass surface, completely wetting the applique application area. Use a clean low lint towel or towelette and wipe the glass, only removing the excess adhesive promoter from the liftgate glass. Do not wipe the glass dry. Allow the liftgate glass to air dry completely. The applique must be installed within 30 minutes following the use of the promoter. Allow the adhesive promoter to remain on the glass surface for a minimum of 10 seconds. Attach the CHMSL wire to the connector and install the grommet. Slide the liftgate glass on the hinge pins to the left in order to allow clearance for the locating hooks. Remove the protective liner from the tape on the applique. Attach the locating hooks on the applique to the hinge pins. Apply the applique to the liftgate glass. With the heel of your hand, and starting from center of the applique and working outward towards each outer edge, apply even and consistent pressure insuring complete contact of the adhesive strip to the glass. Install the screws that retain the applique to the liftgate glass. Tighten Tighten the screws to 5 N.m (44 lb in). The vehicle must be kept dry and at 21°C (70°F) to 43°C (110°F) for no less than 4 hours to ensure proper adhesive cure time. Clean the liftgate glass and applique area. Page 437 Page 12156 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Service Precautions Vehicle Lifting: Service Precautions CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. A/T - Key Will Not Release From Ignition Lock Cylinder Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Locations Automatic Transmission, Left Side Page 13102 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 10589 For vehicles repaired under warranty use, the table. Disclaimer Page 12445 9. Connect the seat cushion heater electrical connector. 10. Install the seat electrical harness to the seat pan. 11. Install the SIR electrical harness (2) to the seat pan. 12. Install the front/rear J strips (2,4). 13. Install the side J strips (1,3). 14. Install the seat pan to the seat adjuster frame. 15. Install the 4 retaining nuts to the studs on the underside of the cushion. Page 11715 1. Position the garnish molding to the liftgate. 2. Install wire harness (1) into the slot located on the garnish molding. 3. Index the locating tabs to the corresponding holes in the liftgate. 4. Index the retaining clips to the liftgate. 5. Push the garnish molding into the liftgate in order to fully seat the retaining clips. 6. Close the liftgate. Garnish Molding Replacement - Windshield Pillar Garnish Molding Replacement - Windshield Pillar Removal Procedure 1. Starting at the top of the garnish molding, carefully release the upper attaching clip that retains the garnish molding to the first pillar. 2. Release the remaining 2 retaining clips from the first pillar. 3. Remove the garnish molding (1) from the vehicle. Installation Procedure 1. Position the garnish molding (1) to the vehicle. 2. Align the locating fingers to the corresponding holes in first pillar. 3. Starting at the top of the garnish molding, seat the attachment clips that retain the garnish molding to the first pillar. Trim Panel Replacement - Rear Quarter - Left - 1 TRIM PANEL REPLACEMENT - REAR QUARTER - LEFT (TRAILBLAZER, ENVOY, BRAVADA) REMOVAL PROCEDURE Page 12190 Driver Door Module (DDM) - C2 Part 1 Page 11685 Scuff Plate: Service and Repair Door Sill Plate Replacement - Lift Gate Door Sill Plate Replacement - Lift Gate Removal Procedure 1. Use a flat-bladed tool in order to release the 4 sill plate retaining tabs. 2. Remove the sill plate from the door frame. 3. Remove any retaining tabs that remain attached to the door frame. Installation Procedure 1. Ensure that all 4 retaining tabs are securly attached to the sill plate. 2. Align the retaining tabs to the liftgate door frame slots. 3. Push down on the sill plate, seating the retaining tabs to the door frame. Page 11796 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 4467 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 8352 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 13672 this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT RECALL CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the Claim Form provided to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. All recall reimbursement questions should be directed to the following number: 1-800-204-0261. Disclaimer Service Procedure Page 3481 English Prevailing Torque Fastener Minimum Torque Development Part 1 Locations Power Window Switch: Locations Door Lock Switch, Window Switch, Driver Door Module (DDM) Page 2998 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield. 3. Remove the electrical connector from the oil pressure switch. 4. Remove the oil pressure switch. Installation Procedure NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the oil pressure switch. Tighten the oil pressure switch to 20 Nm (15 ft. lbs.). 2. Install the electrical connector to the oil pressure switch. 3. Install the engine shield. 4. Lower the vehicle. Page 3009 Timing Chain: Service and Repair Timing Chain, Sprockets, and/or Tensioner Replacement - Tools Required J 36660-A Torque Angle Meter - J 44221 Camshaft Holding Tool Removal Procedure 1. Remove the camshaft cover. 2. Remove the engine front cover. 3. Release the tension on the timing chain by moving the tensioner shoe in. 4. Place the tee into the tensioner to hold the shoe in place. Page 9659 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 4498 Canister Vent Valve: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER VENT VALVE REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the harness connector (2) from the evaporative emission (EVAP) canister vent valve. EVAP Vent Valve 3. Disconnect the EVAP vent pipe (3) from the EVAP canister vent valve (1). 4. Disengage the bracket retaining tab (2) and remove the EVAP canister vent valve. INSTALLATION PROCEDURE Page 8823 Blower Motor Switch: Service and Repair HVAC System - Automatic FRONT AUXILIARY BLOWER MOTOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Press downward and to the right on the front auxiliary blower motor switch. 2. Remove the front auxiliary blower motor switch from the console. 3. Disconnect the electrical connector from the front auxiliary blower motor switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the front auxiliary blower motor switch. 2. Install the front auxiliary blower motor switch to console. 3. Press the front auxiliary blower motor switch into the console. Page 563 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 13187 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the EFS connectors to both (2) EFS's. 3. Install the CPAs to both EFS connectors. 4. Install sensor bracket to bumper. 5. Install the grille. 6. Install the SIR fuse into the fuse block (1) located in the underhood fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 1. Remove the key from the ignition. Page 13974 Steps 5-10 Page 4176 Steps 1-4 The number below refers to the step number on the diagnostic table. 4. If the battery positive voltage and ground circuits of the DLC are functioning properly. The malfunction must be due to the scan tool. Page 7695 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 4. Install the RF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 3. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. Page 9685 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 13905 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 8391 Abbreviations And Meanings Part 11 Page 11503 Lower Side Moulding / Trim: Service and Repair Molding Replacement - Rear Panel Molding Replacement - Rear Panel Removal Procedure 1. Remove the tail lamp assembly from the vehicle. 2. Release the 4 tabs that retain the trim to the tail lamp. 3. Remove the trim from the tail lamp. Installation Procedure 1. Install the trim to the tail lamp, ensuring that the retaining tabs are fully seated. 2. Install the tail lamp assembly to the vehicle. Diagrams Seat Heater Sensor: Diagrams Heated Seat Element And Thermistor Assembly - Driver Back Page 1798 Windshield Washer Switch: Diagrams Rear Window Wiper/Washer Switch Page 10861 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 3633 Chassis Harness, Fuel Tank Page 11008 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Page 1136 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the switch bezel assembly from the seat assembly. 2. Remove the buttons from the switch. 3. Release the tabs that retain the seat switch to the seat bezel assembly. 4. Disconnect the electrical connector from the switch. 5. Remove the seat switch from the seat bezel assembly. Installation Procedure 1. Connect the electrical connector to the switch. 2. Install the seat switch to the seat bezel assembly. Verify that the retaining tabs are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Page 7839 Important: Ensure that the lower control arm is parallel to the lower control arm bracket during the installation and tightening of the lower control arm mounting bolts and nuts. This will ensure correct alignment of the lower control arm bushings. 5. Install the lower control arm to lower control arm bracket mounting nuts. Tighten the nuts to 110 Nm (81 ft. lbs.). Important: There is a washer between the stabilizer shaft link and the lower control arm made of herded steel and has a felt inner liner. Only replace this washer with an identical washer, standard washers should not be used. 6. Install the stabilizer shaft link and washer to the lower control arm. 7. Install the stabilizer shaft link retaining nut. Tighten the nut to 100 Nm (74 ft. lbs.). 8. Install the tire and wheel. 9. Lower the vehicle. 10. Check the front wheel alignment. Upper Control Arm Replacement Upper Control Arm Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the upper ball joint to upper control arm pinch bolt and nut. 4. Disconnect the upper control arm from the steering knuckle. Page 11856 Front Passenger Door Module (FPDM) - C1 Page 7494 C315 Part 1 Page 7488 C309 (Long Wheelbase, Body Type VIN 6) Part 2 C310 Page 2624 9. Remove the ignition control module. 10. Disconnect the engine electrical harness housing from the camshaft cover (1) taking care not to damage the clips that hold the housing in place. 11. Disconnect the fuel injection harness electrical connector. 12. Loosen and remove the camshaft cover bolts. OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 2330 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Page 4228 Page 4806 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Suspension - Boom/Rumble Heard at Highway Speeds Suspension Spring ( Coil / Leaf ): Customer Interest Suspension - Boom/Rumble Heard at Highway Speeds Bulletin No.: 02-03-09-002C Date: December 06, 2004 TECHNICAL Subject: Intermittent Boom, Rumbling Noise and/or Disturbance Heard in Passenger Compartment While Driving at Highway Speeds (Replace Rear Coil Springs) Models: 2002-2005 Chevrolet TrailBlazer 2002-2005 GMC Envoy with Rear Coil Springs 2003-2004 Oldsmobile Bravada with Rear Coil Springs Built Prior to August 23, 2004 (Refer to Parts Information table below for applicable RPO Code usage) Attention: Do not perform this bulletin for vehicles built after 8/23/04. Supercede: This bulletin is being revised to add the breakpoint of 8/23/2004 for 2005 model year production with an updated spring material. Please discard Corporate Bulletin Number 02-03-09-002B (Section 03 - Suspension). Condition Some customers may comment on an intermittent booming, rumbling noise and/or disturbance heard in the passenger compartment while driving the vehicle at highway speeds. This condition occurs while driving at steady speeds between 1550-1700 engine RPM in 4th gear (NOT during acceleration). This equates to 64-80 km/h (48-50 mph) for vehicles with a 4.10 axle ratio (RPO GT5), 83-86 km/h (52-54 mph) with a 3.73 axle ratio (RPO GT4) and 93-96 km/h (58-60 mph) with a 3.42 axle ratio (RPO GU6). Cause The noise/disturbance occurs when the torque converter momentarily goes to a full lock-up state, resulting in zero slip of the torque converter. When the torque converter returns to normal ECCC mode with 30 RPM of slip, the noise will go away. The disturbance generated by the zero slip condition is amplified and transferred into the passenger compartment by the rear coil springs. Correction Replace the rear coil springs using the following service procedure. Note: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 1. Raise and support the vehicle. 2. Support the front frame rail of the vehicle with a suitable adjustable jack stand. 3. Support the rear axle with a suitable adjustable jackstand. 4. Remove the two shock absorber lower mounting bolts. 5. Lower the rear axle enough to remove the tension on the rear coil springs. 6. Remove the rear coil springs. Important: ^ It is critical that the correct coil springs are installed in the correct location. Page 3174 29. Install the auxiliary heater pump and bracket onto the dash panel studs. 30. Reinstall the HVAC plate and nuts. 31. On the coolant bypass valve, remove the hose (1) that went from the valve to the engine and discard. Page 9941 For vehicles repaired under warranty use, the table. Disclaimer Page 10431 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 7134 Application Table Part 3 Diagrams Camshaft Actuator Solenoid Assembly Page 3833 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 356 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 12790 Audible Warning Device: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 4676 Involved are certain 2004 model year Buick Rainier and GMC Envoy XUV; 2002-2004 model year Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles built within the VIN breakpoints shown above. Parts Information Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement in SI. 2. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement in SI. 3. Replace the fuel sender assembly with the new fuel sender assembly provided in the kit. The kit does not provide a new fuel level sensor. Transfer the fuel level sensor from the old fuel sender assembly onto the new fuel sender assembly. Refer to Fuel Sender Assembly Replacement in SI. 4. Install the fuel tank. Refer to Fuel Tank Replacement in SI. Claim Information For vehicles repaired under the terms of this special coverage, submit a claim with the information shown above. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct this condition are to be submitted to the dealer prior to or by October 31, 2009. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Page 12638 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the switch bezel assembly from the seat assembly. 2. Remove the buttons from the switch. 3. Release the tabs that retain the seat switch to the seat bezel assembly. 4. Disconnect the electrical connector from the switch. 5. Remove the seat switch from the seat bezel assembly. Installation Procedure 1. Connect the electrical connector to the switch. 2. Install the seat switch to the seat bezel assembly. Verify that the retaining tabs are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Diagrams Oil Level Sensor For ECM: Diagrams Engine Oil Level and Temperature Sensor Page 4386 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Page 13092 Page 3271 operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. 2. Install the ECT sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. Page 6468 5. Remove the reservoir from the brake master cylinder. 6. Remove the seals from the brake master cylinder. 7. Clean the master cylinder area with denatured alcohol, or equivalent. 8. Dry the master cylinder with non-lubricated, filtered air. Installation Procedure 1. Lubricate the new seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme II (GM P/N 12377967) or equivalent DOT-3 bake fluid from a clean, sealed brake fluid container. 2. Install the lubricated seals, make sure that the seals are fully seated in the brake master cylinder. Page 12534 Abbreviations And Meanings Part 2 Page 98 Steps 1-6 Page 8233 Left AIR TEMPERATURE ACTUATOR REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the I/P carrier. 2. Remove the air temperature actuator-left (1) retaining screws. 3. Disconnect the air temperature actuator-left electrical connector. 4. Remove the air temperature actuator-left. INSTALLATION PROCEDURE 1. Install the air temperature actuator-left (1). 2. Install the air temperature actuator-left retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the air temperature actuator-left electrical connector. 4. Install the I/P carrier. 5. Recalibrate the air temperature actuator on vehicles equipped with automatic climate control (C68), See: Testing and Inspection/Programming and Relearning Right AIR TEMPERATURE ACTUATOR REPLACEMENT - RIGHT Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear bumper fascia. 2. Using a small flat-bladed tool, apply pressure at two upper locations and two lower locations to release the retainers on the pressure relief valve. 3. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Install the rear bumper fascia. Page 12551 Abbreviations And Meanings Part 19 Page 12506 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 8991 1. Remove any dirt, grease, etc. from the mounting surface. 2. Install the SDM horizontally to the vehicle. 3. Point the arrow on the SDM towards the front of the vehicle. 4. Install the nuts that retain the SDM to the floor panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 12 N.m (106 lb in). 5. Connect the electrical connectors (2) to the SDM (1). 6. Return the carpet to the fully installed position. 7. Install the console mounting bracket to the floor panel. 8. Install the floor console. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 8. Page 9787 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 4265 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 512 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 2918 Various symbols in order to describe different service operations. Page 7113 C313 Body - Liftgate Binding/Improper Fit/Rear Glass Broken Trunk / Liftgate Hinge: All Technical Service Bulletins Body - Liftgate Binding/Improper Fit/Rear Glass Broken Bulletin No.: 06-08-66-011A Date: November 08, 2006 TECHNICAL Subject: Rear Liftgate Binds, Improper Fit, Broken Liftgate Glass (Install Welds and Bumpers) Models: 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL Supercede: This bulletin is being revised to add part number information. Please discard Corporate Bulletin Number 06-08-66-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the liftgate or the liftgate glass doesn't fit properly. In some extreme cases, the rear liftgate glass may have broken. Cause A couple of welds may have broken around the upper liftgate hinge(s) or a crack may have formed around the inner two welds. Remove the liftgate and inspect the inner to outer panel welds at the upper hinges. Correction Remove the liftgate trim and electrical wiring from the liftgate. Remove the liftgate and liftgate glass from the vehicle. Straighten the sheet metal at the hinges. Drill four 5/16" holes through the inner panel at the four locations shown in the illustration above. Prepare the sheet metal around the four holes for welding. Clamp the inner and out panel together. Page 12182 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 11016 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the windshield wiper arms. 2. Remove the inlet grille panel retaining nuts and push-pin retainers. 3. Remove the inlet grill panel pushpin retainers. 4. Disconnect the washer hose connection. 5. Remove the inlet grille panel from the vehicle, by pulling upwards in order to disengage the retaining clips. 6. Place the inlet grille panel on a clean, prepared surface. 7. Remove the rear hood seal from the inlet grille panel studs. 8. Remove the rear hood seal from the inlet grille panel. Installation Procedure 1. Position the rear hood seal to the inlet grille panel. 2. Install the rear hood seal to the inlet grille panel studs. 3. Position the inlet grille panel to the vehicle. 4. Press the inlet grille panel downward in order to seat the retaining clips. 5. Push downward on the inlet grille panel to seat the retaining clips. 6. Connect the washer hose connection. 7. install the pushpin retainers. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the inlet grille retaining nuts and push-pin retainers. Tighten the air inlet grille nuts to 4 N.m (35 lb in). 9. Install the windshield wiper arms. Page 6482 9. Install the park brake cable to the mounting bracket, ensuring the locking tabs are secured. 10. Install the rear brake caliper and mounting bracket assembly. 11. Install the tire and wheel assembly. 12. Lower vehicle. Refer to Vehicle Lifting. 13. Enable the park brake automatic adjuster. Page 9545 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 478 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 1460 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 10647 Page 8183 Wheel Fastener: Specifications Wheel Nut 140 Nm 103 lb. ft. Page 6304 Brake Rotor Replacement- Rear Removal Procedure ^ Tools Required J 42450-A Wheel Hub Resurfacing Kit - J 21177-A Drum to Brake Shoe Clearance Gage Caution: Refer to Brake Dust Caution in Service Precautions 1. Inspect the brake fluid level in the brake master cylinder reservoir. 2. If the brake fluid is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, using a appropriate tool, remove the brake fluid to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. Page 12235 Memory Seat Module - Passenger C3 Part 2 Page 2939 Abbreviations And Meanings Part 11 Page 8909 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 3674 Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). Page 9691 Page 6906 Abbreviations And Meanings Part 21 Page 4044 Powertrain Control Module (PCM) C2 Part 6 Page 942 Powertrain Control Module (PCM) C1 Part 2 Page 9376 Abbreviations And Meanings Part 10 Page 126 Page 8650 Hose/Line HVAC: Service and Repair HVAC Pipe Straight Line Repair HEATER AND AIR CONDITIONING (A/C) PIPE REPLACEMENT/REPAIR - AUXILIARY TOOLS REQUIRED J 41425 A/C Line Repair Kit Do not service the rear A/C or heater lines as a complete unit. Service the rear A/C or heater lines as a sectional repair. You can obtain the various sections of line through GMSPO. Use the J 41425 when any of the following actions damage the rear A/C or heater lines: - Rub-through - Collision damage - Leakage in the system Minimum Tube Length Required Table IMPORTANT:When sectioning the rear A/C or heater lines, ensure that the correct minimum length remains in the straight part of the line on both sides of the splice. Follow the Straight Line Repair procedure in order to repair line damage in a straight section of line. Follow the Line Sectioning Repair procedure in order to repair any damage in a bend area. Do not repair the rear A/C or heater lines in a bend area, replace the lines. Maintaining the original line shape will prevent vibrations and rub-through. Straight Line Repair 1. Recover the refrigerant, if repairing the A/C lines. 2. Drain the coolant, if repairing the heater lines. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Locate the area that requires repair. 5. Obtain a length of replacement line to make the repair. 6. Use a tubing cutter in order to cut and remove the section of damaged line. 7. Use a tubing cutter in order to cut the replacement line to length. Page 13232 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 11808 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 3747 Steps 4-7 Page 7833 Control Arm: Specifications Upper Control Arm Mounting Bolts 111 ft. lbs. Page 11924 3. Install the screw that retains the seat control module to the seat pan. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat module screw to 3 N.m (26 lb in). 4. Install the seat pan to the seat assembly. 5. Install the nuts which retain the seat pan to the seat assembly. Tighten Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 6. Install the 3 seat switch bezel screws. Page 2796 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 5262 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Page 9428 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 8908 6. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 7. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 8. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 9. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. 10. Install the SIR fuse to the fuse block (1) located in the underhood electrical center. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition. Page 8606 1. Use the J 26549-E in order to install the expansion tube. IMPORTANT:Install the shorter screen end of the expansion tube into the evaporator tube (6) first. 2. Install the new O-ring seal. 3. Assemble the evaporator tubes (4,6). 4. Install the evaporator tube nut. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the nut to .....28 N.m (21 lb ft). 5. Connect the evaporator tube (4) to the evaporator (1). 6. Install the nut (3). Tighten Tighten the nut to .....28 N.m (21 lb ft). 7. Install the coolant reservoir. 8. Install the accumulator. 9. Recharge the refrigerant system. 10. Leak test the fittings of the components using the J 39400. Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 13981 The table will be used to measure the resistance of the sensor and compare it with the actual ambient temperature. The mirror's temperature accuracy should be within 5° of the actual temperature. The actual temperature should not be taken from a radio station, a sign displaying the temperature, etc. A temperature measuring tool such as a thermometer should be used. Some temperature measuring tools may be within 5° of the actual temperature. Make sure to consult the manufacturer for the accuracy of the tool. This comparison can make the mirror seem off by 5° to 10° of the actual temperature when it is not. TEST Page 6353 1. If the brake caliper guide pin is to be reused, clean the brake caliper guide pin using denatured alcohol, or equivalent. 2. Dry the brake caliper guide pin using non-lubricated, filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper guide pin. DO NOT apply lubricant to the brake pad hardware. 4. Install the front brake caliper to the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the front brake caliper mounting bolts. ^ Tighten the front brake caliper mounting bolts to 51 Nm (38 ft. lbs.). Important: DO NOT reuse the metal/copper gaskets. Use only new metal/copper gaskets. 6. Install the NEW metal/copper gaskets to the front brake caliper bolt. 7. Install the front brake hose bolt and gaskets. ^ Tighten the brake hose bolt to 54 Nm (40 ft. lbs.). 8. Bleed the hydraulic brake system. 9. Install the tire and wheel assembly. 10. Lower the vehicle. Refer to Vehicle Lifting. Rear Brake Caliper Replacement - Rear Page 3640 Intake Air Temperature (IAT) Sensor Page 12869 Page 9823 Abbreviations And Meanings Part 15 A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 12850 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 6922 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram Page 6767 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 10687 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 12627 Seat Adjuster Switch Driver (w/o Memory) Part 2 Page 9025 12. Install the seat switch bezel. Heated Oxygen Sensor (HO2S) 1 Replacement Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 1 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). 2. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must install the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. 2. Install the heated oxygen sensor (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Page 2660 Drive Belt Falls Off Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. The drive belt may have been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Page 1149 1. Position the memory seat switch to the lock and door lock and side window switch (1). 2. Connect the electrical connector (2) to the memory seat switch. 3. Install the door lock and side window switch (1). Verify that the front retaining clips and the rear retaining clips are fully seated. Page 12434 Disclaimer Page 9660 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 7098 C304 Part 1 Page 12397 Lumbar Adjuster Switch - Driver (w/ Memory) Air Distribution Ducts Air Duct: Service and Repair Air Distribution Ducts Replacement AIR DISTRIBUTOR DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP assembly 2. Remove the driver side air distributor duct screws. 3. Remove the air distributor duct (1) from the instrument panel. INSTALLATION PROCEDURE 1. Install the air distributor duct (1) to the instrument panel. 2. Install the retaining screws to the air distributor duct. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to .....1.9 N.m (17 lb in). 3. Install the IP assembly. Replacement - Auxiliary (Lower) AIR DISTRIBUTION DUCTS REPLACEMENT - AUXILIARY (LOWER) Page 7091 C201 Part 3 Page 1754 Abbreviations And Meanings Part 18 Description and Operation Daytime Running Lamp: Description and Operation DAYTIME RUNNING LAMPS (DRL) The ambient light sensor is a light sensitive transistor that varies its voltage signal to the body control module (BCM) in response to changes to the outside (ambient) light level. When the BCM receives this signal it will either turn on the daytime running lamps (DRL) through the HDM using the reduced output or the headlamps at full intensity for auto headlamp operation. Any function or condition that turns on the headlights will cancel the daytime running lamps operation. The daytime running lamps (DRL) are the low beam headlights at a reduced intensity. With the headlight switch in the OFF position, the headlights will either be turned ON or OFF, after an approximate 8 second delay depending on whether daylight or low light conditions are sensed. When the BCM signals the HDM for DRL operation in daylight conditions, the HDM illuminates the low beam headlights at a reduced intensity. The DRL will operate when the ignition switch is in the RUN position, the gear selector is not in the PARK position and the parking brake is released. When these conditions have been met and the ambient light sensor indicates daytime conditions, the DRL will illuminate. On vehicles equipped with the 4-position headlamp switch, the DRL feature can be temporarily disabled by momentarily placing the headlamp switch in the DRL defeat position. This will signal the BCM to disable the DRL function until the headlamp switch is momentarily placed in the DRL defeat position again or until the next ignition key cycle. DRL operation in Manual Transmission equipped vehicles will occur when the ignition switch is in the RUN position, and the parking brake is released. Page 11930 1. Position the memory seat switch to the lock and door lock and side window switch (1). 2. Connect the electrical connector (2) to the memory seat switch. 3. Install the door lock and side window switch (1). Verify that the front retaining clips and the rear retaining clips are fully seated. Page 5445 For vehicles repaired under warranty, use the table. Disclaimer Page 4376 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. 2. Install the APP sensor retaining fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 4401 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. 1. Install the CKP sensor into the engine block. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 6230 Registered And Non-Registered Trademarks Part 3 Page 9377 Abbreviations And Meanings Part 11 Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: Customer Interest Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13020 Abbreviations And Meanings Part 21 Specifications Idle Speed: Specifications Engine Speed ...................................................................................................................................... .......................................................... 500 - 700 RPM Desired Idle Speed .............................................................................................................................. ........................................................ PCM Controlled Page 10820 Page 3223 Disclaimer Page 351 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 99 Steps 1-2 Locations Engine Page 7241 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 9139 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Accessory Delay Module DIAGNOSTIC STARTING POINT - ACCESSORY DELAY MODULE Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The Diagnostic System Check will provide the following information: - Class 2 communication status - "U" codes which indicate module communication or circuit failure - "B" codes which indicate a possible body function or circuit failure - The status of any "U" or "B" codes Diagnostic System Check - Accessory Delay Module DIAGNOSTIC SYSTEM CHECK - ACCESSORY POWER MODULE TEST DESCRIPTION Steps 1-3 Page 4216 Body Control Module (BCM) Page 8174 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Coolant Heater Engine Block Heater: Service and Repair Coolant Heater Coolant Heater Replacement (4.2L Engine) Removal Procedure 1. Drain the engine coolant. 2. Remove the PCM. 3. Remove the harnesses from the engine harness bracket. 4. Remove the bolt that secures the engine harness bracket and remove the bracket. 5. Remove the coolant heater cord from the heater (2). 6. Remove the coolant heater from the block. Page 10118 Page 11992 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Only if necessary remove the fuel tank shield. IMPORTANT: Due to an access hole in the fuel tank shield, removal of the shield should not be necessary to access the fuel pressure service connection. 3. Remove the fuel pressure service connection cap, located near the fuel filter. 4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Turn ON the ignition. 6. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 8. Command the fuel pump ON with a scan tool. 9. Close the bleed valve on the fuel pressure gage. 10. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. Page 210 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Specifications Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Mounting Bolt 12 ft. lbs. Page 4152 Information Bus: Electrical Diagrams Data Link Connector (DLC) Diagram 1 Page 10326 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 3502 Abbreviations And Meanings Part 19 Page 246 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 12457 INSTALLATION PROCEDURE 1. Install the cover to the cushion. 2. Install the reinforcement bar to the hog-rings. 3. Attach the retaining strips that retain the cover to the cushion. 4. In order to install the seat cushion to the seat pan, perform the following: 5. Install the seat pan to the cushion and cover assembly. 6. Compress the foam and install the seat cover and cushion to the seat pan. 7. Connect the J-strips that retain the cover to the seat pan. 8. Install the push pins (1) on the underside of the seat bottom. Page 6905 Abbreviations And Meanings Part 20 Page 847 Conversion - English/Metric Part 2 Page 7341 Fuse Block - Rear C4 Part 1 Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Radiator Support Shield Replacement Skid Plate: Service and Repair Radiator Support Shield Replacement Radiator Support Shield Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the radiator support shield mounting nuts and bolts. 3. Remove the radiator support shield. Installation Procedure 1. Remove the radiator support shield. Notice: Refer to Fastener Notice in Service Precautions. 2. Remove the radiator support shield mounting nuts and bolts. Tighten the radiator support shield mounting nuts to 17 N.m (13 lb ft). 3. Lower the vehicle. Locations Oxygen Sensor: Locations Engine, Right Side Diagrams Heater Control Valve: Diagrams Coolant Bypass Valve (Body Type VIN 6) (w/Manual - HVAC System) Page 1124 Seat Adjuster Switch - Driver (w/o Memory) Part 1 Page 12153 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 6878 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 12399 Lumbar Adjuster Switch - Passenger (w/Heat) Page 3456 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 12614 Position Sensor - Recline Motor (w/Memory) Page 7231 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Valve Lash Adjuster Replacement Tools Required - J 36660-A Torque Angle Meter - J 44222 Camshaft Sprocket Holding Tool Removal Procedure 1. Remove the camshaft cover. 2. Remove the exhaust and the intake sprocket bolts. 3. Install the J44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components. 4. Carefully move the sprockets with the timing chain off of the camshafts. Important: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed. 5. Remove the camshaft cap bolts. 6. Remove the camshaft caps. Page 5551 9. Pull the primary lock (1) up. Spring tension will push the end of the cable past the ball stud. Important: If the cable end is pushed rearward past the ball stud during the adjustment procedure, it must be released and allowed to come forward of the ball stud. The cable end must then be pushed back just enough to be installed to the ball stud. 10. Push the end of the cable until it is aligned with the ball stud. 11. Install the cable (4) to the ball stud (6). 12. Seat the primary lock (1) by pressing into the locked position. Page 13485 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 419 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 4050 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. - Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. Removal Procedure 1. Loosen the PCM harness connector bolts (1) from the center of the PCM harness connectors. 2. Remove the PCM harness connectors (3) from the PCM (2). NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 3. Remove the PCM mounting nuts and bolts (4). 4. Remove the PCM (2) from the intake manifold. NOTE: Refer to PCM and ESD Notice in Service Precautions. 5. Remove the PCM mounting studs from the intake manifold, if necessary. Installation Procedure Page 2479 Vehicle Lifting Points The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: - Beneath the lower control arms, inboard from the shock absorber mounts - Beneath the center of the front crossmember Page 11659 25. Peel the carpet forward and up over the front seats. Note that the carpet hooks around the wheel house panel stud. 26. Remove the headliner harness from the left-hand third pillar. 27. Remove the headliner harness from the floor studs. 28. Remove the third pillar headliner harness electrical connector from the body electrical block, and the block base from the floor panel. 29. Reach underneath the carpet and disconnect the 6-way headliner harness electrical connector (1) from the cross-body wire harness. 30. Remove the navigational antenna cable from the right-hand third pillar. 31. Remove the navigational antenna cable from the floor studs. 32. Pull the communication interface module electrical connectors back through the hole in the carpet. 33. Remove the cellular antenna coax cable from the inner coupling on the left body side window. Page 10212 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Diagrams Engine Oil Level and Temperature Sensor HVAC System - Manual Control Assembly: Description and Operation HVAC System - Manual HVAC SYSTEM - MANUAL AIR DELIVERY HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings.The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM.The body control module (BCM), which is the vehicle mode master, provides a device on signal.The control module supports the features as in the table. AIR TEMPERATURE HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings.The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the features as in the table. Page 3549 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 8405 Abbreviations And Meanings Part 25 Page 4425 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE 1. Install the knock sensor (1 or 2) and the bolt (3). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 1527 For vehicles repaired under warranty, use the table. Disclaimer Page 416 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 7464 C108 Part 1 Page 10625 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 862 Abbreviations And Meanings Part 7 Page 7918 3. Connect the air spring compressor electrical connection (2). 4. Connect the air inflator switch electrical connection, air supply line, and air spring compressor vent hose to the air spring compressor. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the air spring compressor to the frame mounting bolts. Tighten the air spring compressor to the frame mounting bolts to 25 Nm (18 lb ft). 6. Lower the vehicle. 7. Install the air suspension system fuse. 8. Start the vehicle and run for approximately 1 minute to ensure that the air spring leveling system is functioning properly. 9. Check D height. 10. Check for leaks. If a leak is found at the air supply lines connections at the air spring compressor, replace the air supply lines. Page 12511 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Fuel System - Fuel Spit-Back/Early Pump Nozzle Shut-Off Fuel Filler Neck: Customer Interest Fuel System - Fuel Spit-Back/Early Pump Nozzle Shut-Off Bulletin No.: 04-06-04-003A Date: August 11, 2004 TECHNICAL Subject: Vehicle is Difficult to Fill with Fuel or Filling Station Pump Shuts Off Before Tank is Full or Fuel Spits Back/Out When Filling Tank (Replace Fuel Tank Filler Upper Pipe and Lower Hose) Models: 2003 Chevrolet TrailBlazer with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2003 GMC Envoy with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2003 Oldsmobile Bravada with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL 2004 Buick Rainier 2004 Chevrolet TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Envoy XUV 2004 Oldsmobile Bravada Built Prior to December 2003 Supercede: This bulletin is being revised to provide new part number for 2002-2003 vehicles. Please discard Corporate Bulletin Number 04-06-04-003 (Section 06 - Engine/Propulsion System). This bulletin provides information on two different conditions. Condition 1 Some customers may comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. Cause This condition may be caused by the variability (fuel flow rates, type of fuel fill nozzle, fuel properties) at the filling stations. There is a potential to develop an increase in back pressures internal to the fuel fill neck. This back pressure trips the fuel nozzle prior to filling the tank, or results in a hard to fill condition. Condition 2 Some customers may comment that when filling the fuel tank, a small amount of fuel may spit back/out. Cause This condition may be caused by the equalization of pressure between the fuel tank and the fuel fill neck that does not react quickly to the variance in the pressure when the fueling station fuel nozzle trips off. Correction Replace the fuel tank filler upper pipe assembly with P/N 88983256 or P/N 15131043, and lower hose assembly with P/N 15131046. The new upper pipe has been redesigned to provide smoother flow conditions within the section and the lower hose has been redesigned to include a checking feature. Use the procedure listed below. 1. Remove the fuel fill cap. 2. Remove the fuel fill pipe housing. Page 13307 Lifgate Ajar Switch Page 3066 Disclaimer Page 3881 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Diagrams Engine Oil Level and Temperature Sensor Page 4659 Steps 20-22 Page 8290 3. Install the sensor (1) to the panel assembly (2). 4. Install the front grille. Page 3449 Page 13904 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 4751 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Page 7133 Application Table Part 2 Page 12617 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Part 1 Page 10339 Conversion - English/Metric Part 2 Page 11825 Abbreviations And Meanings Part 10 Page 4409 Chassis Harness, Fuel Tank Page 10327 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 6059 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Locations Page 12229 Memory Seat Module - Driver C4 Part 1 Page 6995 Location View Page 13471 Disclaimer Specifications Brake Fluid: Specifications Hydraulic Brake System Delco Supreme 11 Brake Fluid GM Part No. 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid. Page 4496 Evaporative Emission (EVAP) Canister Vent Solenoid Page 9904 Page 6714 Generator: Service and Repair REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Remove the drive belt. 3. Disconnect the battery positive cable nut (1) on the generator. 4. Remove the A/C line mounting bracket bolt at the engine life hook. 5. Remove the right engine lift hook bolts and remove the lift hook. Page 2293 Oil Change Reminder Lamp: Service and Repair GM OIL LIFE SYSTEM RESETTING When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL message will come on. Change the engine oil as soon as possible within the next 600 miles (1000 km). It is possible that, if driving under the best conditions, the oil life may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system us ever reset accidentally, change the engine oil at 3000 miles (5000 km) since last oil change. With the Driver Information Center (DIC) 1. Press the fuel information button until ENGINE OIL LIFE appears in the display. 2. To reset the monitor, press and hold the select button while ENGINE OIL LIFE is displayed. Without the Driver Information Center (DIC) To reset the CHANGE ENGINE OIL light, do the following: 1. Turn the ignition key to RUN, with the engine off. 2. Full press and release the accelerator pedal slowly 3 times within 5 seconds. 3. If the CHANGE ENGINE OIL light flashes for five seconds, the system is reset. If the light does not flash, repeat the procedure. 4. Turn the key to LOCK. If the CHANGE ENGINE OIL light comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the procedure. Page 12008 WA160E/06 - WA228A/55 A/T - Shift Lock Control Actuator Available Shift Interlock Solenoid: Technical Service Bulletins A/T - Shift Lock Control Actuator Available Bulletin No.: 05-07-129-001B Date: February 16, 2007 INFORMATION Subject: Automatic Transmission Shift Lock Control Actuator Available for Service Use Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2006 Chevrolet TrailBlazer EXT 2003-2006 Chevrolet SSR 2002-2007 GMC Envoy 2002-2006 GMC Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add the SSR. Please discard Corporate Bulletin Number 05-07-129-001A (Section 07 - Transmission/Transaxle). The automatic transmission shift lock control actuator is now available for service as a separate part. The actuator was formerly available only as part of the entire shifter assembly. DO NOT replace the shifter assembly if the shift lock control actuator requires replacement. Please refer to the Automatic Transmission Shift Lock Control Actuator Replacement procedure in the Automatic Transmission sub-section of the Service Information. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 1756 Abbreviations And Meanings Part 20 Page 7206 For vehicles repaired under warranty, use the table. Disclaimer Suspension - Front/Rear Suspension Pop/Clunk/Snap Noises Stabilizer Link: All Technical Service Bulletins Suspension - Front/Rear Suspension Pop/Clunk/Snap Noises TECHNICAL Bulletin No.: 05-03-08-007A Date: March 31, 2008 Subject: Rattle, Clunk, Pop, Snap Noise from Front and/or Rear Suspension While Driving Over Rough, Uneven, Wash Board Road Surfaces (Replace Appropriate Stabilizer Link(s)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to update the Warranty information. Please discard Corporate Bulletin Number 05-03-08-007 (Section 03 - Suspension). Condition Some customers may comment on a rattle, clunk, pop, loose lumber-type noise coming from the front and/or rear suspension while driving over rough uneven roads. Cause The front and/or rear stabilizer links, may develop additional clearance in the ball joint links leading to a noise concern. Correction 1. Road test the vehicle and verify if the noise is coming from the front or rear, left or right of the vehicle. It is possible in some circumstances that the noise may be coming from the front and rear suspension. 2. Once it is determined that the noise is coming from the front or rear, left or right of the vehicle, raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information (SI Document ID # 1253321). Caution: DO NOT DRIVE the vehicle on highways or at a high rate of speed while the stabilizer link(s) are removed/disconnected from the vehicle. ONLY test drive the vehicle in a parking lot or on a side street. Driving the vehicle with the link(s) removed/disconnected may reduce vehicle stability. 3. Remove or disconnect the suspect stabilizer link(s) from the appropriate stabilizer shaft and re-road test the vehicle with the links disconnected to verify the source of the noise. ^ If the noise is still present with the suspect link(s) removed the source of the noise is NOT the stabilizer links. Refer to the information below for diagnostic assistance. ^ Service Bulletin - Rattle From Front of Vehicle (Adjust Hood Latch Following New Procedure) # 03-08-63-003 or newer (SI Document ID # 1410372) ^ Service Bulletin - Rattle Noise Under Hood (Reposition Hood Prop Rod) # 04-08-63-005 or newer (SI Document ID # 1527265) ^ Service Information - Suspension - Suspension General Diagnosis in the appropriate SI Document. ^ If the noise is no longer present with the suspect stabilizer link(s) removed continue with the next step. 4. Replace the suspect stabilizer link(s) (see parts information below). Refer to the appropriate Service Information for the replacement procedure. Page 6263 7. Remove the rear brake caliper from the brake caliper mounting bracket. Installation Procedure 1. If the brake caliper guide pin is to be reused, clean the brake caliper guide pin using denatured alcohol, or equivalent. 2. Dry the brake caliper guide pin using non-lubricated, filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper guide pin. DO NOT apply lubricant to the brake pad hardware. 4. Install the rear brake caliper assembly to the mounting bracket. Locations Automatic Transmission, Left Side Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: Customer Interest Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 10514 Page 11013 outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the Locations Sunroof / Moonroof Module: Locations Roof With Headliner Removed Page 994 Disclaimer Page 10136 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 5744 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (13 in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. 10. Remove the TCC solenoid retaining bolts. Page 5486 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Page 11644 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 4. Connect the IP module yellow 4-way connector (1) located behind the IP support. 5. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. Page 6288 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Page 11458 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6376 Disclaimer Service Procedure Tools Required (for brake pipe replacement, if required) J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent J 35589-A Brake Pressure Bleeder Adapter The following procedure provides instruction for inspecting, and if necessary, replacing the brake pipe located between the left front brake caliper flex hose and the ABS modulator. Inspection Procedure 1. Place the vehicle on a suitable hoist and turn the steering wheel to the full right. 2. Open the hood. 3. Raise and support the vehicle. 4. Clean and remove any dirt from the left front brake pipe and flare nut (3) where it connects to the left front caliper flex hose (4). 5. Carefully inspect the brake pipe where it goes into the flare nut for a tooling mark (1) as shown above. The mark may be located at any point around the circumference of the pipe and a mirror and flashlight may be required to see it. There will NOT be any of the spiral lines or grooves (2) in the tooling mark. ^ If the tooling mark IS present (1), then the brake pipe does NOT need to be replaced. Lower the vehicle and install the GM Recall Identification Label. Page 10784 Steering Column Page 10883 Abbreviations And Meanings Part 19 Page 7101 C305 Part 2 Page 8925 1. Remove any dirt, grease, etc. from the mounting surface. 2. Install the SDM horizontally to the vehicle. 3. Point the arrow on the SDM towards the front of the vehicle. 4. Install the nuts that retain the SDM to the floor panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 12 N.m (106 lb in). 5. Connect the electrical connectors (2) to the SDM (1). 6. Return the carpet to the fully installed position. 7. Install the console mounting bracket to the floor panel. 8. Install the floor console. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 8. Page 8243 5. Install the right rear quarter trim panel. Left AIR TEMPERATURE ACTUATOR REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the I/P carrier. 2. Remove the left side air temperature actuator (1) retaining screws. 3. Disconnect the left side air temperature actuator electrical connector. 4. Remove the left side air temperature actuator. INSTALLATION PROCEDURE 1. Install the left side air temperature actuator (1). 2. Install the left side air temperature actuator retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector to the left side air temperature actuator. 4. Install the I/P carrier. 5. Calibrate the air temperature actuator on vehicles equipped with automatic climate control (C68), See: Testing and Inspection/Programming and Relearning Right Page 610 Abbreviations And Meanings Part 22 Page 4183 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 8104 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 4189 Manifold Absolute Pressure (MAP) Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 3. Press the retainer locking tabs inward, then pull the retainer (1) up to remove it. 4. Remove the MAP sensor (2). 5. Inspect the MAP sensor seal for damage, and replace as necessary. INSTALLATION PROCEDURE Page 13276 Abbreviations And Meanings Part 14 Page 13926 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 12149 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 1318 Stop Lamp Switch Page 5760 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 1843 Steps 10-13 Page 12330 Installation Procedure 1. Install the guides to the seat back frame, verifying that the lower retainers are fully seated to the frame. 2. Install the guide with the locking tab (1) on the seat's right-hand side. 3. Install the seat back cover and pad. 4. Install the front seat head restraint. 5. Install the seat assembly. Head Restraint Cover Replacement - Front Seat Head Restraint Cover Replacement - Front Seat Removal Procedure 1. Remove the front seat head restraint. 2. Release the J-strips on the bottom of the head restraint cover. 3. Remove the cover from the head restraint. Installation Procedure Page 10088 For vehicles repaired under warranty use, the table. Disclaimer Page 1534 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 12669 Air Dam: Service and Repair Air Dam Replacement - Front (Chevrolet , GMC) Air Dam Replacement - Front (Chevrolet, GMC) Removal Procedure 1. Remove the front fascia. 2. Remove the impact bar. 3. Disengage the tabs on the air deflector from the slots in the impact bar. 4. Remove the air deflector from the impact bar. Installation Procedure 1. Install the air deflector to the impact bar. 2. Insert the tabs on the air deflector to the slots in the impact bar. 3. Install the impact bar. 4. Install the fascia. Electrical - Intermittent Interior Electrical Concerns Hazard Warning Flasher: All Technical Service Bulletins Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 13855 Vanity Lamp: Description and Operation VANITY MIRROR LAMPS The inadvertent power courtesy lamps supply voltage circuit of the BCM provides battery positive voltage to each vanity mirror lamp. When the vanity mirror cover on the sunshade is opened, a switch closes to provide a ground circuit and the vanity lamp illuminates. Page 10210 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 9328 Page 7737 Steering Gear: Service and Repair Rack and Pinion Boot Replacement - Off Vehicle Rack and Pinion Boot Replacement - Off Vehicle Tools Required ^ J22610 Keystone Clamp Pliers Removal Procedure 1. Remove the outer tie rod. 2. Remove the rack and pinion gear. Important: All boot parts must be replaced when replacing the inner tie rod. 3. Remove and discard the small seal retaining clamp (1). 4. Remove and discard the large seal retaining clamp (1) from the rack and pinion boot (2) with side cutters. Page 1740 Abbreviations And Meanings Part 4 Page 8754 A/C Low Pressure Switch (w/Automatic - HVAC System) Page 13684 this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT RECALL CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the Claim Form provided to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. All recall reimbursement questions should be directed to the following number: 1-800-204-0261. Disclaimer Service Procedure Page 7687 6. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 7. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Zone 6 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the RF door trim panel. Page 9129 Page 3919 Abbreviations And Meanings Part 6 Locations Engine, Left Front Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Page 1706 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11 Page 4814 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 5471 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Slde Page 13146 Abbreviations And Meanings Part 18 Page 584 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 4291 Abbreviations And Meanings Part 25 Page 5735 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Page 12245 Power Trunk / Liftgate Control Module: Diagrams Endgate Module (EGM) Endgate Module (EGM) C1 (XUV) Page 10000 Page 4190 1. Install the MAP sensor (2). 2. Install the MAP sensor retainer (1). 3. Connect the electrical connector. Page 9004 5. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 6. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Locations Instrument Panel Page 10601 Disclaimer Page 9767 Page 6631 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 3752 Steps 20-22 Page 8635 1. Apply coolant to the end of the heater inlet hoses. 2. Install the heater inlet hose to the inlet hose fitting at the engine block. IMPORTANT:When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 3. Install the nut retaining the coolant bypass valve to the cowl. Tighten Tighten the nut to ......10 N.m (89 lb in). 4. Install the inlet heater hose to the engine block. 5. Reposition the inlet heater hose clamp at the engine block using J 38185. 6. Install the quick connect end of the inlet heater core hose to the heater core. 7. Install the coolant recovery reservoir. 8. Fill the engine cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6) in Cooling System. Page 6645 Generator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 2367 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 6743 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Page 1995 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator support diagonal brace if applicable. 2. Remove the radiator air intake baffle if applicable. 3. Loosen the three air cleaner cover/resonator retaining screws (2) one shown, and remove the cover/resonator (1). 4. Lift the air cleaner element (1) and air outlet duct (3) from the lower air cleaner housing/washer solvent tank assembly (2). 5. Remove the air cleaner element (1) by grasping the air cleaner element and removing it from the air outlet duct (3) with a twisting and pulling motion. 6. Inspect the entire assembly for debris or damage and repair as necessary. INSTALLATION PROCEDURE Page 1816 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 7523 6. Connect the mobile telephone harness connector (1) to the junction block. 7. Connect the instrument panel harness connector (1) to the block base. 8. Install the junction block to the block base. Ensure that the retaining tabs are fully seated. Page 6826 Registered And Non-Registered Trademarks Part 4 Page 8511 HVAC Control Module-Auxiliary, With Rear Seat Audio (Body Type VIN 6) Part 2 Page 5357 The new thread size 9/16-1a UNF-2A (1) was implemented on 11-29-07 or Julian date 333. Disclaimer Page 9465 For vehicles repaired under warranty use, the table. Disclaimer Page 13126 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 12174 Abbreviations And Meanings Part 19 Page 3987 operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. 2. Install the ECT sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. Page 9795 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 6972 Fuse Block - Underhood C2 Part 2 Page 2262 Application Table Part 4 Location View Page 4254 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 10516 Page 2942 Abbreviations And Meanings Part 14 Page 5166 Shift Solenoid: Diagrams 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Slde Page 6839 Page 3576 Powertrain Control Module (PCM) C1 Part 2 Page 6493 13. Install the park brake cables to the retainer. 14. Install the park brake cables to the park brake equalizer. 15. Install the rear propeller shaft. 16. Lower the vehicle. Refer to Vehicle Lifting. 17. Enable the park brake automatic adjuster. 18. Test the park brake operation. 19. Adjust the park brake cables. Body - Center Mount Brake Lamp Applique loose Center Mounted Brake Lamp: Customer Interest Body - Center Mount Brake Lamp Applique loose Bulletin No.: 01-08-66-007C Date: August 27, 2007 TECHNICAL Subject: Center High-Mount Stop Lamp (CHMSL) Applique Loose (Re-Tape Applique) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2008 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to include additional model years and change step 7 in the procedure. Please discard Corporate Bulletin Number 01-08-66-007B (Section 08 - Body and Accessories). Condition Some customers may comment that the CHMSL applique is loose on the liftgate glass. Cause A poor bonding of the double-sided adhesive tape between the CHMSL applique and the liftgate glass may cause this condition. Correction Re-tape the CHSML applique to the liftgate glass using the following service procedure: Open the liftgate glass. Remove the screws that retain the applique to the liftgate glass. Do not damage the applique or the liftgate glass when removing the applique from the liftgate glass. With a flat-bladed tool, carefully remove the applique from the liftgate glass. Remove the CHMSL harness grommet from the roof panel. Disconnect the CHMSL harness connector. Place a clean fender cover on a suitable working surface and place the applique on the fender cover. Remove the old adhesive from the underside of the applique. (For Saab Only Remove the two screws from the CHMSL and remove the CHMSL from the applique. Remove all the ribs from the back side of the applique as seen in illustration above. Clean the applique and the CHMSL with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984 or equivalent, and dry thoroughly using a clean low lint towel or towelette. Apply double-sided adhesive tape, 3M(R) P/N 06397 or equivalent to the CHMSL lens as seen in the illustration below and install the two screws and tighten). Tighten Page 3648 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 2183 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 4. Install the RF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 3. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. Page 6080 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Sealing Washer A/C Coupler O-ring: Service and Repair Sealing Washer SEALING WASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the seal washer from the A/C refrigerant component. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. IMPORTANT:Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. 4. Discard the sealing washer. IMPORTANT:DO NOT reuse sealing washer. INSTALLATION PROCEDURE 1. Inspect the new seal washer for any signs of cracks, cuts, or damage.Do not use a damaged seal washer. IMPORTANT:Flat washer type seals do not require lubrication. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. IMPORTANT:After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C Page 12195 Mirror Switch, Driver Door Module (DDM) - C5 Page 6222 Abbreviations And Meanings Part 21 Page 9413 Page 3485 Abbreviations And Meanings Part 2 Page 571 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 8794 Control Module HVAC: Service and Repair Control Module HVAC - Auxiliary Auxiliary Heater and Air Conditioning Control Module Replacement Removal Procedure 1. Using a flat bladed tool, carefully pry out on the top of the HVAC control-auxiliary. 2. Remove the HVAC control-auxiliary from the center console/seat. 3. Disconnect the electrical connector. 4 remove the HVAC control-auxiliary. Installation Procedure Service and Repair Fluid Transfer Tube: Service and Repair Filler Tube and Seal Replacement Removal Procedure 1. Remove the filler tube indicator. 2. Remove the nut (2) securing the filler tube to the exhaust manifold stud (1). 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Position a drain pan under the vehicle. 5. Remove the filler tube (1) and seal (2) from the vehicle. Installation Procedure Page 5217 In some cases, the customer may not comment about a vibration but it is important to test drive the vehicle while using the electronic vibration analysis tool in an attempt to locate the cause of the torsional vibration. Refer to the Vibration Diagnosis and Correction sub-section of the appropriate Service Manual for more details on diagnosing and correcting vibrations. Disclaimer Page 12986 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 9191 Abbreviations And Meanings Part 24 Page 10595 For vehicles repaired under warranty, use the table. Disclaimer Page 12332 2. Verify that the retaining clips are fully seated. 3. Install the rear seat head restraint posts to the head restraint retractor, verifying that the notches in the head restraint posts are indexed toward the back of the seat. 4. Lower the head restraint to the full down position. Head Restraint Guide Replacement - Rear No. 1 Head Restraint Guide Replacement - Rear No. 1 Removal Procedure 1. Remove the head restraint. 2. Remove the seat back cover and pad high enough to expose the head restraint guides. 3. Remove the head restraint guides by squeezing the retaining tabs (1) located at the bottom of the guides together. Installation Procedure 1. Install the head restraint guides by pushing the guides into the frame until the retaining tabs (1) lock the guide in place. 2. Install the seat back cover and pad to the seat back. 3. Install the head restraint. Head Restraint Retractor Assembly Replacement - Rear No. 1 Head Restraint Retractor Assembly Replacement - Rear No. 1 Removal Procedure Caution: Refer to Prevent Accidental Deployment of the Head Restraint Retractor Assembly in Service Precautions. 1. Remove the seat back cover and pad. Page 9423 Page 7643 25. Reinstall the pump reservoir cap. Excessive Vacuum Drop Diagnosis 1. If the vacuum continues to drop, remove the pressure and return hose from the pump. 2. Install the plugs (1, 2) supplied with the J43485 into the pressure and return port. 3. Attach the J43485 to the J35555 or equivalent. 4. Place the J43485 on or in the pump reservoir filler neck. 5. Apply a vacuum of 68 kPa (20 in Hg) maximum. 6. If the vacuum drops again, repair or replace the pump. If the vacuum holds steady, continue to check the other parts of the steering system. Important: Fluid must be free from bubbles and foam. Be aware of periodic bubbles that indicate a loose connection or leaking O-ring seal in the return hose or the pressure hose. Fluid must be free from discoloration. 7. Observe the fluid. 8. If condition persists, replace the following parts: ^ The return hose clamps ^ The return hose O-rings Page 6787 Conversion - English/Metric Part 1 Page 1649 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Page 2099 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 13673 1. Remove the 2 screws that retain the insulator panel to the instrument panel (I/P). 2. Release the insulator panel retaining clip from the I/P substrate. 3. Lower the insulator panel. 4. Remove the flasher retaining bracket from the insulator panel. 5. Disconnect the flasher from the electrical connector. 6. Remove the flasher from the vehicle. 7. Position the new flasher to the insulator panel. 8. Connect the electrical connector to the flasher. 9. Install the flasher retaining bracket to the insulator panel. 10. Install the insulator panel tabs to the cowl slots. 11. Raise the insulator panel to the I/P. 12. Install the insulator panel retaining clip to the I/P substrate. 13. Install the 2 screws that retain the insulator panel to the I/P. Tighten Tighten the screws to 2.5 N.m (22 lb in). Page 3710 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 269 Parts Information Page 598 Abbreviations And Meanings Part 10 Page 1592 Disclaimer Page 3774 Disclaimer Diagrams Transmission Range Switch Connector, Wiring Harness Side Page 10921 6. Install the rear electrical center cover. 7. If replacing the body wiring harness extension on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 8. If replacing the body wiring harness extension on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 9. Connect the negative battery cable. Page 6255 Brake Caliper: Service and Repair Brake Caliper Overhaul Front Brake Caliper Overhaul- Front ^ Tools Required J 8092 Driver Handle - J 43885 Boot Seal Installer Disassembly Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions 1. Drain all the brake fluid from the caliper. 2. Pad the interior of the caliper with clean shop towels. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding. 3. Remove the pistons (2) from the caliper bores. 4. Remove the boots (1) from the caliper bores. Do not scratch the caliper bores. 5. Remove the piston seals (3) from the caliper bores. Do not use a metal tool. 6. Remove the bleeder valve cap (4). 7. Remove the bleeder valve (5) from the caliper housing (6). 8. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 9. Replace the pistons or the caliper if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston Chrome plating damage on the piston ^ Corrosion in the caliper bore Use a crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore Assembly Procedure Page 12510 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 1116 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Part 2 Page 9768 Page 1271 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch (w/Manual - HVAC System) Page 871 Abbreviations And Meanings Part 16 Page 7474 Multiple Junction Connector: Diagrams C301 - C316 C301 Part 1 Page 2952 Abbreviations And Meanings Part 24 Page 9971 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 1939 Spark Plug: Testing and Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 7477 C304 Part 1 Page 1732 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 3181 47. Connect the electrical connector to the A/C low pressure switch. 48. Install the lower air cleaner housing/washer solvent tank assembly onto the mounting studs. 49. Install the two air cleaner housing/washer tank assembly retaining nuts to the mounting studs. 50. Connect the washer pump hoses. 51. Connect the washer solvent tank electrical and install wiring harness to the retaining clips. 52. Install the air inlet duct to the lower air cleaner housing/washer solvent tank assembly. 53. Install the air cleaner filter element and air outlet duct. 54. Install the air cleaner cover. 55. Install the tender rear upper brace. 56. Connect the negative battery cable. 57. Recharge the refrigerant system. 58. Fill the cooling system. 59. Inspect the cooling system for leaks. 60. Leak test the refrigerant fittings using J 39400-A. Parts Information Warranty Information Page 10864 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 7127 C900 Page 4144 Registered And Non-Registered Trademarks Part 4 Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Drain and Refill ..................................................................................................... ............................................................................................ 4.7L (5.0 Qt) Service Precautions Vehicle Lifting: Service Precautions CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Page 3158 16. Remove the nut and bolt securing the coolant recovery reservoir. 17. Remove the coolant recovery reservoir with the accumulator attached. 18. Remove the evaporator tube nut at the evaporator. 19. Remove the evaporator tube from the evaporator 20. Using the J 43181, disconnect the heater hoses from the core. 20.1. Install the J 43181 to the heater core hose. 20.2. Close the tool around the heater core hose. 20.3. Firmly pull the tool into the quick connect end of the heater hose. 20.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 21. Disconnect the coolant bypass valve hose from the auxiliary rear heater line. 22. Disconnect the coolant bypass valve hose from the engine. 23. Disconnect the electrical connector from the coolant bypass valve. This connector will no longer be used. Tape off with electrical tape. 24. Disconnect the vacuum hose from the coolant bypass valve. 25. Remove the nut retaining the coolant bypass valve to the cowl and remove the coolant bypass valve with hoses attached. 26. Remove the heater hose quick connect retainers from the heater core pipes. 27. Remove the four nuts and the HVAC plate from the dash panel. 28. Attach the new auxiliary heater pump to the new bracket using the supplied retainers as shown. Note the position of the pump on the bracket. Page 5746 16. Remove the manual detent spring retaining bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages. 19. Remove the remaining control valve body bolts. 20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the check bails (1-7) in the valve body. Page 11176 9.1. Replace the latch assembly. 9.2. Proceed to Step 11. 10. If two distinct audible clicks are heard: 10.1. Ensure that the fork bolt is in the fully latched position. 10.2. Blow out the latch in the area of the detent with compressed air. 11. Lubricate both sides of the detent pivot by spraying with GM Superlube for one second, and then cycle the latch open and closed several times to work the lubrication into the pivot. 12. Repeat Steps 1 through 11 for the rear door on the other side. Page 9052 2. Install a new grommet (1). 3. Install the seat assembly in the vehicle. Page 12082 WA9539/47 - WA9792/39 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12710 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 13880 Inside Rearview Mirror Page 326 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 13094 Page 6570 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front passenger side seat. 2. Remove the park brake warning lamp switch electrical connector. 3. Remove the park brake warning lamp switch retaining screw. 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch retaining screw. ^ Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). 3. Connect the electrical connector. 4. Install the front passenger side seat. Page 10616 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 4357 Engine Control Module: Diagrams Powertrain Control Module (PCM) C2 Powertrain Control Module (PCM) C2 Part 1 Page 12468 4. Install the seat module, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the seat module retaining screw. Tighten the screw to 5 N.m (44 lb in). 6. Install the 11 hog rings to the top side of the cover and pad. 7. Install the 2 hog rings (1) to the bottom rear side of the cover and pad. 8. Press the seat cover hook and loop retaining strips together by running your hand firmly over the seat cover. 9. Connect the seat cushion heater electrical connector. 10. Install the seat electrical harness to the seat pan. 11. Install the SIR electrical harness (2) to the seat pan. 12. Install the front/rear J strips (2,4). 13. Install the side J strips (1,3). Page 2869 Intake Manifold: Specifications Intake Manifold Bolt 89 inch lbs. Page 7201 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 864 Abbreviations And Meanings Part 9 Page 264 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 13946 Abbreviations And Meanings Part 16 Page 10500 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 9471 For vehicles repaired under warranty, use the table. Disclaimer Page 4110 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 5871 Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5549 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11219 Rear Door Weatherstrip: Service and Repair Sealing Strip Replacement - Rear Door Upper Sealing Strip Replacement - Rear Door Upper Removal Procedure 1. Starting at the bottom of the sealing strip, pull the sealing strip away from the door pinch-weld flange. 2. Lift upward in order to remove the upper portion of the sealing strip from the door pinch-weld flange. 3. Remove the sealing strip from the door. Installation Procedure 1. Starting at the top of the sealing strip, insert the sealing strip tab into the door sheet metal. 2. Position the sealing strip to the door pinch-weld flange and apply pressure in order to seat the sealing strip. 3. Ensure that the sealing strip is fully seated against the pinch-weld flange. Page 2259 Fuse Block: Application and ID Underhood Fuse Block Location View Application Table Part 1 Page 13185 11. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 12. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 13. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 14. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 9 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 10507 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 11968 For vehicles repaired under warranty use, the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty use, the table. Page 13835 Turn Signal Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the left closeout/insulator panel. 2. Remove the flasher retaining bracket from the insulator panel. 3. Disconnect the flasher from the electrical connector. 4. Remove the flasher from the vehicle. INSTALLATION PROCEDURE 1. Position the flasher to the insulator panel. 2. Connect the electrical connector to the flasher. 3. Install the flasher retaining bracket to the insulator panel. 4. Install the left closeout/insulator panel. Page 2244 Fuse Block - Underhood C4 Part 3 Page 9839 Registered And Non-Registered Trademarks Part 5 Page 4411 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Page 909 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). 7. Disconnect the body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. Page 12721 Disclaimer Page 2053 Radiator Hose: Service and Repair Outlet Body VIN Code 3 Radiator Hose Replacement - Outlet (Body Vin Code 3 / GMT 360) Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the engine coolant. 2. Reposition the inlet radiator hose clamp (2) at the radiator using J 38185. 3. Remove the inlet radiator hose from the radiator. 4. Reposition the inlet radiator hose clamp (1) at the engine outlet using J 38185. 5. Remove the inlet radiator hose from the engine. Installation Procedure 1. Install the inlet radiator hose clamps (1, 2) to the radiator hose. 2. Install the inlet radiator hose to the engine. 3. Reposition the inlet radiator hose clamp (1) using J 38185. 4. Install the inlet radiator hose to the radiator. 5. Reposition the inlet radiator hose clamp (2) using J 38185. 6. Fill the cooling system. Body VIN Code 6 Radiator Hose Replacement - Outlet (Body Vin Code 6 LL8 / GMT 370) Tools Required J 38185 Hose Clamp Pliers Page 11692 9. Position the inboard retainer (1) to the roof panel. 10. Install the inboard retaining screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 1.2 N.m (10 lb in). 11. With the sunshade parallel to the windshield, index the pivot arm tab to the roof panel slot. 12. Apply and maintain upward pressure to the pivot arm while rotating the sunshade parallel to the side window. The sunshade arm should appear flush with the bezel. 13. Rotate and clip the sunshade to the inboard retainer. 14. Ensure the pivot arm retaining tabs are fully seated to the roof panel. 15. Install the front assist handle to the roof panel. 16. Install the windshield garnish molding. 17. Install the center pillar trim panel. 18. Return the bucket seat to an upright position. Page 7107 C308 Page 7377 Application Table Part 3 Page 13939 Abbreviations And Meanings Part 9 Page 11155 Disclaimer Service Procedure 1. Ensure that the rear rocker panel in the tape contact area (1) is clean and dry. Use a non oil based cleaner, preferably isopropyl alcohol. For Chevrolet TrailBlazer EXT with molded-in-color rear rocker, coat the top of the rocker with adhesion promoter, P/N 12378462 (U.S.), 10953554 (Canada), or equivalent and then allow it to dry. 2. With the door closed, trace the contour of the door using a china marker or grease pencil. Hold the taper of the marker to the door as shown. Page 2886 Page 9597 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 2739 6. Install the engine oil drain plug. ^ Tighten the engine oil drain plug bolt to 26 Nm (19 ft. lbs.). 7. Lower the vehicle. 8. Fill the crankcase with the proper quantity of engine oil. Page 6656 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Service and Repair Power Steering Line/Hose: Service and Repair Power Steering Hose Assembly Replacement Tools Required ^ J44586 Power Steering Gear Oil Seal Remover/Installer Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Raise the vehicle and support with suitable safety stands. 2. Install a drain pan under the vehicle. 3. Remove the power steering hose assembly to the power steering gear retaining bolt. 4. Disconnect the power steering hose assembly from the power steering gear. 5. Remove the power steering return hose and power steering cooler hose from the power steering cooler. 6. Lower the vehicle. 7. Disconnect the fuse block wiring harnesses from the wiring loops. 8. Remove the fuse block. 9. Remove the battery tray. Page 10372 Abbreviations And Meanings Part 25 Page 207 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 5648 Transmission Cooler: Description and Operation Transmission Oil Cooler The transmission oil cooler is a heat exchanger. It is located inside the right side end tank of the radiator. The transmission fluid temperature is regulated by the temperature of the engine coolant in the radiator. The transmission oil pump, pumps the fluid through the transmission oil cooler line to the transmission oil cooler. The fluid then flows through the cooler where the engine coolant absorbs heat from the fluid. The fluid is then pumped through the;transmission oil cooler return line, to the transmission. Page 34 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 4629 1. Lubricate the new injector O-ring seals (2, 4) with clean engine oil. 2. Install the new injector O-ring seals on the injector. 3. Install a new retainer clip (1) on the injector. 4. Push the fuel injector into the fuel rail injector socket with the electrical connector facing outward. The retainer clip locks on to a flange on the fuel rail injector socket. 5. Install the fuel rail assembly. Page 4625 Fuel Injector: Testing and Inspection Fuel Injector Circuit Diagnosis CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. DIAGNOSTIC AIDS - Monitoring the fuel injector circuit status with a scan tool, while moving the fuel injector harness, may help isolate an intermittent condition. - Performing the Fuel Injector Coil Test may help isolate an intermittent condition. Refer to Fuel Injector Coil Test. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics - For an intermittent condition, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies TEST Steps 1-2 Page 874 Abbreviations And Meanings Part 19 Page 12248 Power Trunk / Liftgate Control Module: Service and Repair LIFT GATE CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the liftgate window garnish molding. 2. Remove the liftgate trim panel. 3. Disconnect the electrical connectors (3) from the module as necessary. 4. Remove the bolts that retain the module to the liftgate. 5. Remove the module from the liftgate. INSTALLATION PROCEDURE 1. Install the module to the liftgate. 2. Install the bolts that retain the module to the liftgate. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Connect the electrical connectors (3) as necessary. 4. Install the liftgate trim panel. 5. Install the liftgate window garnish molding. 6. Reprogram the liftgate control module. Refer to Lift Gate Control Module Programming. Page 3300 1. Apply coolant to the end of the heater inlet hoses. 2. Install the heater inlet hose to the inlet hose fitting at the engine block. IMPORTANT:When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 3. Install the nut retaining the coolant bypass valve to the cowl. Tighten Tighten the nut to ......10 N.m (89 lb in). 4. Install the inlet heater hose to the engine block. 5. Reposition the inlet heater hose clamp at the engine block using J 38185. 6. Install the quick connect end of the inlet heater core hose to the heater core. 7. Install the coolant recovery reservoir. 8. Fill the engine cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6) in Cooling System. OnStar(R) - Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 9366 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 7515 Location View Page 4813 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 4956 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON(R) transmission fluid. Page 10770 For vehicles repaired under warranty, use the table. Disclaimer Page 1699 Page 2243 Fuse Block - Underhood C4 Part 2 Page 191 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 13182 6. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 7. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Zone 6 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the RF door trim panel. Latch Replacement - Lift Gate Trunk / Liftgate Latch: Service and Repair Latch Replacement - Lift Gate Latch Replacement - Lift Gate Removal Procedure 1. Remove the liftgate window garnish molding. 2. Remove the liftgate trim panel. 3. Disconnect the outside handle rod from the bellcrank. 4. Disconnect the bellcrank rod from the latch/lock assembly. 5. Remove the screws that retain the bellcrank to the latch/lock. 6. Remove the bellcrank from the latch/lock. 7. Disconnect the electrical connector from the latch assembly. 8. Disconnect the lock cylinder bellcrank rod (1) from the latch assembly. 9. Remove the screws that retain the latch/lock assembly to the liftgate. 10. Remove the latch/lock assembly from the liftgate. Installation Procedure Page 6935 Fuse: Application and ID Fuse Block - Rear (Long Wheelbase) Location View Sunroof Drain Hose Replacement - Front Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Hose Replacement - Front SUNROOF DRAIN HOSE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement (TrailBlazer, Envoy, Bravada)Headliner Replacement (TrailBlazer EXT, Envoy XL) in Interior Trim. 2. Disconnect the front sunroof drain hose from the sunroof module front spigot, right or left side, as needed. 3. Remove the 2 hose clips securing the drain hose to the cowl panel, right or left side, as needed. 4. Remove the 2 hose clips securing the drain hose to the side door frame, right or left side, as needed. 5. Remove the drain hose from the vehicle, right or left side, as needed. Leave the mechanic's wire behind the instrument panel. IMPORTANT: In order to aid in installation, attach a mechanic's wire to the end of the hose. INSTALLATION PROCEDURE OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 1628 Electronic Components Page 8306 33. Install the new hose, # 1003 (L6 engine) or # 1004 (V8 engine) onto the auxiliary heater pump inlet port. Connect the other quick connect end to the engine. Page 6768 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 3555 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 13028 Registered And Non-Registered Trademarks Part 3 Page 1155 4. Install the overhead console to the roof. Page 10845 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Locations Power Seat Page 6923 Auxiliary Power Outlet: Service and Repair CIGAR LIGHTER HOUSING OR 12 VOLT ACCESSORY POWER RECEPTACLE REPLACEMENT TOOLS REQUIRED J 42059 Cigarette Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the 12 volt power supply or cigar lighter fuse. 2. Remove the socket by placing one side of the "T" portion of the tool J 42059 into the socket and into the square window tab. 3. Position the opposite "T" portion of the tool into the opposing square window tab. 4. Pull the socket straight out of the retaining ring. 5. Remove the tool from the socket. 6. Disconnect the electrical connector from the socket. Page 3900 5. Tape over the entire cable. Use a winding motion when you apply the tape. OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 9431 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 626 Mirror Connector, Driver Door Module (DDM) - C3 Part 2 Page 8262 6. Release retaining clips (2) from the defroster duct (1). 7. Remove the defroster duct (1). INSTALLATION PROCEDURE 1. Install the defroster duct. 2. Insert defroster duct into retaining slots. 3. Install the driver side window defroster duct. Page 8126 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the ABS sensor mounting bolt from the wheel hub and bearing. 5. Remove the ABS sensor from the wheel hub and bearing. 6. Remove the wheel hub and bearing to the steering knuckle mounting bolts. 7. Remove the wheel hub and bearing from the steering knuckle. 8. Remove the splash shield from the steering knuckle. Locations Instrument Panel Page 5938 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 8348 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 6975 Fuse Block - Underhood C2 Part 5 OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Page 5705 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Page 6843 Page 3496 Abbreviations And Meanings Part 13 Page 688 Sunroof Module Page 13411 Page 12662 Quarterglass Switch - L OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 2204 Application Table Part 2 Page 1384 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. 2. Disconnect the negative battery terminal. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the Page 340 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 10057 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Locations Automatic Transmission, Left Side Page 2619 NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 7. Install the camshaft caps onto their original journal. Tighten the camshaft cap bolts to 12 Nm (106 inch lbs.). 8. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222. 9. Install the intake camshaft sprocket washer, and the bolt, and the exhaust camshaft actuator bolt. - Tighten the intake camshaft sprocket bolt the first pass 20 Nm (15 ft. lbs.). - Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100°. - Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 ft. lbs.). - Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135°. 10. Install the camshaft cover. Page 10881 Abbreviations And Meanings Part 17 Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor (VSS) Page 2893 Page 1807 Wiper Switch: Service and Repair WIPER/WASHER SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the instrument panel (IP) accessory trim plate. 2. Disconnect the electrical connector from the wiper washer switch. 3. Release the wiper washer switch locking tabs. 4. Remove the switch from the trim plate. INSTALLATION PROCEDURE 1. Position the switch to the trim plate. 2. Connect the electrical connector to the wiper washer switch. 3. Install the switch to the instrument panel trim plate, ensuring that the locking tabs are properly seated. 4. Install the instrument panel (IP) accessory trim plate. Page 2035 Hose/Line HVAC: Service and Repair Evaporator Tube Air Conditioning Evaporator Tube Replacement Tools Required - J 26549-E Orifice Tube Remover - J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. 2. Loosen the evaporator tube (5) from the evaporator. 3. Loosen the auxiliary evaporator tube (7) from the auxiliary piping. 4. Remove the evaporator tube nut from the condenser. 5. Remove the nuts (1, 2) retaining the evaporator tube to the fender. 6. Remove the washer solvent container. 7. Remove the coolant recovery tank. 8. Remove the evaporator tube using J 26549-E. 9. Remove the O-ring seal and discard. Installation Procedure 1. Install the new O-ring seal. Page 4611 Fuel Injector 6 Page 9771 Page 7343 Fuse Block - Rear C4 Part 3 Diagrams Seat Heater Sensor: Diagrams Heated Seat Element And Thermistor Assembly - Driver Back Page 13032 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 2635 2. Install the valve spring and the valve spring retainer. 3. Use the J 44228 and compress the valve springs. 4. Install the valve keys. 5. Remove the J 44228. Page 1225 Air Temperature Sensor-Upper Right Page 4045 Engine Control Module: Diagrams Powertrain Control Module (PCM) C3 Powertrain Control Module (PCM) C3 Part 1 Page 9138 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 5728 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Page 6690 Abbreviations And Meanings Part 12 Page 11847 Registered And Non-Registered Trademarks Part 6 Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE 1. Insert a small coin between the two halves of the transmitter case at the slot provided near the key ring hole. 2. Twist the coin in order to open the case. 3. Open the transmitter case. 4. Remove the battery. NOTE: Refer to Handling ESD Sensitive Parts Notice in Service Precautions. INSTALLATION PROCEDURE 1. Install the battery with the positive (+) side down. Use one 3 volt, type CR2032 battery, or the equivalent. 2. Ensure that the seal is in position. 3. Align the two halves of the case together and squeeze the case closed until the tabs are fully seated. Page 2855 Oil Pick Up/Strainer: Specifications Oil Pump Pickup Tube 89 inch lbs. Page 4837 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE 1. Install the knock sensor (1 or 2) and the bolt (3). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 10498 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 3952 Body Control Module (BCM) C3 Part 1 Page 391 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 4038 Powertrain Control Module (PCM) C1 Part 5 Page 10468 For vehicles repaired under warranty, use the table. Disclaimer Service and Repair Horn Switch: Service and Repair Horn Switch Replacement Removal Procedure Caution: Refer to Servicing the SIR System Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the Inflatable Restraint Steering Wheel module. 3. Remove the horn plunger from the steering column by pressing inward to the stop and rotating horn plunger 90 degrees. 4. Disconnect the horn contact plate:(2) captured screws (1, 4) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure Universal Joint Replacement - Nylon Injected Ring Universal Joint: Service and Repair Universal Joint Replacement - Nylon Injected Ring Universal Joint Replacement - Nylon Injected Ring Tools Required ^ J9522-3 U Joint Bearing Separator ^ J9522-5 U Joint Bearing Spacer Remover Disassembly Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller shaft as to which end is the transmission end and which end goes to the rear axle. 3. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 inch) socket. 4. In order to shear the plastic retaining ring on the bearing cup, place J9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 5. If you do not completely remove the bearing cup, lift the cross and insert J9522-5 between the seal and the bearing cup you are removing. Continue to press the bearing cup out of the yoke. 6. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 7. Mark the orientation of the slip yoke to the tube for proper reassembly. 8. Remove the cross from the yoke. 9. Remove the remaining universal joint parts from the yoke. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 10. Inspect the retaining ring grooves for plastic. 11. Inspect the bearing cup bores in the yoke ears for burrs or imperfections. 12. Clean the remains of the sheared plastic bearing retainers from the grooves in the yoke. Page 6851 Page 6984 Fuse Block - Underhood C7 Page 11079 For 2007 vehicles repaired under warranty, use the table. Disclaimer Page 4322 2. Connect the 24-way gray electrical connector (1) to the BCM. 3. Connect the 32-way tan electrical connector (2) to the BCM. 4. Connect the body wiring extension (1) to the BCM. 5. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. Page 13504 Clearance Lamp: Service and Repair CLEARANCE LAMP REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the headlamp switch. 2. Insert a small flat bladed tool under the rear edge of the lens and pry upward. 3. Remove the lens. 4. Twist the bulb counterclockwise to remove. INSTALLATION PROCEDURE 1. Insert the bulb into the bulb socket and twist clockwise to install. 2. Insert the forward edge of the lens into the opening and press the rear edge downward to install. Page 7334 Fuse Block - Rear C2 Part 3 Page 117 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 7476 C303 (With RPO Code Z70) Page 6991 Fuse Block: Application and ID Fuse Block - Rear (Short Wheelbase) Location View Page 10838 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 4162 Steps 16-18 Page 13631 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Open the left instrument panel (IP) access cover. 2. Reach into the access hole and release the 4 retaining tabs located on the headlamp switch behind the IP. 3. Remove the headlamp switch from the IP, through the IP access hole. 4. Disconnect the electrical connectors from the headlamp switch. 5. Remove the headlamp from the IP. INSTALLATION PROCEDURE Page 8521 2. Install the HVAC control module (2) to the instrument panel (4), ensuring that the HVAC control module retaining tabs (3) lock into place. 3. Install the HVAC control module retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to .....1.9 N.m (17 lb ft). 4. Install the IP accessory trim plate. 5. Start the vehicle and let run for one minute. IMPORTANT:Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating.If interrupted improper HVAC performance will result. Auxiliary HVAC CONTROL MODULE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Using a flat bladed tool, carefully pry out on the top of the HVAC control-auxiliary. 2. Remove the HVAC control-auxiliary from the center console/seat. Page 9105 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 2 and SIR Disabling and Enabling Zone 6. CAUTION: Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the front door trim panel. 3. Peel the rear half of the water deflector away from the door in order to access the side impact sensor. 4. Remove the screws that retain the side impact sensor (2) to the door. 5. Disconnect the impact sensor electrical connector (1) from the side impact sensor. 6. Remove the side impact sensor from the door. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Position the side impact sensor (2) horizontally to the door. 3. Connect the electrical connector (1) to the side impact sensor (2). 4. Install the screws which retain the side impact sensor to the door. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Page 12808 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 9048 Tighten Tighten the front seat belt buckle nut to 52 N.m (38 lb ft). 3. Connect the seat belt reminder wiring harness (3) on the driver's seat. 4. Install the front seat assembly. Page 13517 Courtesy/Reading Lamp - Right Center (Body Type VIN 6) Control Module HVAC Control Module HVAC: Service and Repair Control Module HVAC HVAC Control Module Replacement Removal Procedure 1. Remove the I/P accessory trim plate. 2. Remove the HVAC control module screws. 3. Depress the HVAC control module tabs (3) and remove the HVAC control module (2) from the I/P (4). 4. Disconnect the electrical connectors (1) from the HVAC control module (2). Installation Procedure 1. Connect the electrical connectors (1) to the HVAC control module (2). Important: Ensure that the HVAC control module tabs (3) lock into place. 2. Install the HVAC control module (2) into the I/P (4). Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the HVAC control module screws. Tighten the screws to 1.9 Nm (17 in. lbs.). 4. Install the I/P accessory trim plate. Page 10037 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 3649 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE 1. Install the knock sensor (1 or 2) and the bolt (3). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 7614 4. Loosen the lower control arm adjustment bolts (1). Adjust the caster and the camber angle by repositioning the lower control arm (2) until the specifications have been met. 5. When the adjustments are complete, hold the lower control arm in position so that the specifications do not change while tightening the lower control arm adjustment bolts. TIGHTEN ^ Front lower control arm bracket mounting bolts to 260 Nm (192 lb ft). ^ Rear lower control arm bracket mounting bolts to 240 Nm (177 lb ft). 6. Verify that the caster and the camber are still within specifications. When the caster and camber are within specifications, adjust the toe. Front Wheel Toe Adjustment Front Toe Adjustment 1. Loosen the jam nut on the outer tie rod (2). Notice: Care must be taken that the boots are not: twisted when rotating the inner tie rods, or damage to the boots may result. 2. Rotate the inner tie rod (1) to the required toe specification setting. 3. Tighten the jam nut on the outer tie rod. Tighten the outer tie rod jam nut to 75 Nm (55 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Page 3476 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Specifications Brake Fluid: Specifications Hydraulic Brake System Delco Supreme 11 Brake Fluid GM Part No. 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid. Page 10898 Body Control Module: Connector Views Body Control Module (BCM) C1 Part 1 Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Page 6264 Notice: Refer to Fastener Notice in Service Precautions. 5. Install the rear brake caliper on the mounting bracket. ^ Tighten the brake caliper mounting bolts to 31 Nm (23 ft. lbs.). 6. Install the NEW metal (copper) gaskets on the brake hose bolt. 7. Remove the plug from the brake hose end. 8. Install the brake hose bolt on the rear brake caliper. ^ Tighten the brake hose bolt to 44 Nm (33 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting Page 3443 Knock Sensor (KS) 1 Front Knock Sensor (KS) 1 Front Page 11704 1. Starting at the top of the garnish molding, carefully release the upper attaching clip that retains the garnish molding to the first pillar. 2. Release the remaining 2 retaining clips from the first pillar. 3. Remove the garnish molding (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the garnish molding (1) to the vehicle. 2. Align the locating fingers to the corresponding holes in first pillar. 3. Starting at the top of the garnish molding, seat the attachment clips that retain the garnish molding to the first pillar. Page 8556 A/C Coupler O-ring: Service and Repair O-Ring O-RING REPLACEMENT REMOVAL PROCEDURE 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure - For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). - For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. 5. Cap or tape the A/C refrigerant components. IMPORTANT:Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 6. Discard the O-ring seal. INSTALLATION PROCEDURE 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. IMPORTANT:DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. IMPORTANT:DO NOT reuse O-ring seals. Page 3950 Body Control Module (BCM) C1 Part 2 Page 6051 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Slde A/C - Musty Odors On Start Up Control Module HVAC: Customer Interest A/C - Musty Odors On Start Up Bulletin No.: 05-01-39-002A Date: March 17, 2006 TECHNICAL Subject: Musty Odor from HVAC System (Reprogram HVAC Control Module to Enable Afterblow Function) Models: 2004-2006 Buick Rainier 2003-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2003-2004 Oldsmobile Bravada with Automatic Temperature Control HVAC System (RPO CJ2) Supercede: This bulletin is being revised to add the 2006 model year and update the calibration release date. Please discard Corporate Bulletin Number 05-01-39-002 (Section 01 - HVAC). Condition Some customers may comment on a musty odor from the Heating, Ventilation and Air Conditioning (HVAC) system. This condition occurs most often on initial start up after the vehicle was driven on a hot humid day. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. Correction Important: The afterblow function should not be enabled until after the purpose and operation of it is explained to your customer and they approve of the change. Once the afterblow function is enabled there are no calibrations currently released to disable it. Technicians are to reprogram the HVAC Control Module with an updated software calibration that will enable the afterblow function. The new calibration will be released beginning with TIS satellite data update version 2.0, which was made available February 5, 2006. The blower motor will turn on approximately 10 minutes after the vehicle is shut off. The blower motor will run continuously for 10 minutes at a 30% duty cycle. The afterblow function will only activate if the air conditioning compressor was engaged during conditions of high ambient temperature. If the vehicle is started within 10 minutes of the last key off, the afterblow function from the previous key cycle will be cancelled. Technicians should not attempt to reprogram a vehicle with a Manual Temperature Control HVAC system (RPO CJ3). Technicians should perform this HVAC Control Module reprogram instead of installing the Electronic Evaporator Dryer Module Kit referred to in the Air Conditioning Odor bulletin, Corporate Bulletin Number 99-01-39-004A. Warranty Information Page 4604 Fuel Injector 3 Page 3629 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Page 8601 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to .....1.9 N.m (17 lb in). 5. Install the HVAC module assembly. Page 3655 1. Install the MAP sensor (2). 2. Install the MAP sensor retainer (1). 3. Connect the electrical connector. Page 11578 There may be a lack of sealer under the "A" pillar reveal molding push nuts. Refer to the illustration above. Cause 4 The push-in retainers at the base of the auxiliary weatherstrip may not be seated fully. Refer to the illustration above. Cause 5 There may be a gap between the many pieces of sheet metal under the primary seal flange. If this is present, water may enter under the primary seal retainer and into the vehicle between the gaps in the sheet metal flange and end up under the carpet. Refer to the illustration above. Correction 1 Page 9159 Conversion - English/Metric Part 2 Recall - Tail/Stop Lamp Inspection/Replacement Technical Service Bulletin # 04087 Date: 041116 Recall - Tail/Stop Lamp Inspection/Replacement Product Safety - Tail Lamps/Stop Lamps # 04087 - (Nov 16, 2004) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002-2004 Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, Oldsmobile Bravada, and 2004 Buick Rainier vehicles. In some of these vehicles, vibration and heat may cause the tail lamp/stop lamp bulb to loosen in its socket. If this occurs, the bulb may flicker and eventually become inoperative. The center high mounted stop lamp and turn signal functions are not affected and will operate as designed. The loss of one or both of the tail lamp/stop lamps could reduce the vehicle's visibility to following drivers and fail to warn others that the vehicle is braking and/or is stopped, which could lead to a vehicle crash. Correction Dealers are to inspect the tail lamp/stop lamp assemblies, and if necessary, replace them. Vehicles Involved Involved are certain 2002-2004 Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, Oldsmobile Bravada, and 2004 Buick Rainier vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor (VSS) Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: Customer Interest Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 10531 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 7211 Disclaimer Locations Engine, Left Front Page 6201 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 1052 20. Remove the backing material from the seal, align it over the wiper motor cover so that it completely covers the vent (2), and press it firmly into place as shown in the above illustration. Apply firm pressure across the entire surface of the seal and around all outside edges. Continue applying pressure a second time to the edges to assure full adhesion. 21. Position the wiper module to the vehicle and connect the electrical connector. 22. Install the wiper module in the plenum sheet metal. 23. Install the two 10 mm hex head bolts that attach the module to the plenum sheet metal. Tighten Tighten the bolts to 8 N.m (71 lb in). 24. Install the air inlet grille to the plenum sheet metal. 25. Install the 10 mm hex head nut that attaches the left and right ends of the air inlet grille to the plenum sheet metal. Tighten Tighten the nuts to 4 N.m (35 lb in). 26. Install the antenna mast. Important If installing a NEW wiper module, you must verify that the new wiper motor and transmissions are in the PARK position before installing the wiper arms. 27. If installing a NEW wiper module, turn the ignition switch to the ON position, turn the wiper switch ON, and visually verify that the wiper transmissions operate. After visually verifying operation, turn the wiper switch to the OFF position and allow the wiper transmissions to stop moving before turning the ignition switch to the OFF position. The wiper motor will now be in the PARK position. 28. Using the marks or masking tape that were placed on the windshield, align and position the wiper arms on the wiper transmission shafts. 29. Install the nuts on the wiper transmission shafts. Tighten Tighten the nuts to 30 N.m (22 lb ft). 30. Install the covers on the wiper arm nuts. 31. Remove the marks or masking tape from the windshield. 32. Open the hood. 33. Install the three push-in retainers that attach the air inlet grille to the plenum sheet metal. 34. Close the hood. 35. Verify that all functions of the wiper system (low, high, delay, etc.) operate properly. Page 4932 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 4350 Engine Harness, Fuse Block-Underhood Brake Pads Replacement Brake Pad: Service and Repair Brake Pads Replacement Front Brake Pads Replacement - Front Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. 1. Inspect the brake fluid level in the brake master cylinder reservoir. 2. If the brake fluid is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove the brake fluid with appropriate tool to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. Page 343 Circuit/System Testing Component Testing Page 12797 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 5854 1. Install the axle shaft into the rear axle housing. 2. Slide the axle shaft into place allowing the splines to engage the differential side gear. 3. On axles without a locking differential, place the C-lock on the button end of the axle shaft. 4. On axles with a locking differential, keep the pinion shaft partially withdrawn. 5. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2). 6. Pull the shaft flange outward in order to seat the C-lock in the differential gear. Page 9544 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 8065 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 3475 Conversion - English/Metric Part 2 Page 3980 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Page 8 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 3013 4. Install the cylinder head access hole plugs. Tighten the cylinder head access hole plugs to 5 Nm (44 inch lbs.). 5. Install the J44221 with the camshaft flats up and the number 1 cylinder at top dead center. 6. Install the crankshaft sprocket (1). 7. Install the intake camshaft sprocket into the timing chain. 8. Align the dark link of the timing chain with the timing mark on the intake camshaft sprocket (1). 9. Feed the timing chain down through the opening in the head. 10. Install the timing chain on the crankshaft sprocket. Align the dark link of the timing chain with the timing mark on to the crankshaft sprocket. Important: It may be necessary to remove J 44221 to rotate and hold the camshaft (hex) to align the pin to the camshaft sprocket. 11. Install the intake camshaft sprocket onto the intake camshaft. 12. Install the intake camshaft sprocket washer and bolt. Page 4792 Crankshaft Position (CKP) Sensor Page 8334 Page 11663 25. Reach underneath the carpet and install the 6-way headliner harness electrical connector (1) to the cross-body wire harness. 26. Pass the communication interface module electrical connectors through the small hole in the carpet. 27. Install the headliner harness retaining clips to the rocker panel and the floor panel. 28. If equipped with OnStar(R) perform the following procedure: 1. Install the navigation antenna cable to the right 'C' pillar. 2. Install the navigation antenna cable to the floor studs. 29. Install the body electrical block. 30. Install the rear carpet. Ensure that the carpet hooks over the left wheelhouse panel stud. 31. Connect the electrical connector to the left-hand body side window actuator. 32. Connect the electrical connector to the right-hand body side window actuator. Page 13897 Heated Glass Element: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 4624 Steps 6-8 The number below refers to the step number on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. Page 4154 Information Bus: Description and Operation DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The data link connector (DLC) allows a scan tool to communicate with the class 2 serial data line. The serial data line is the means by which the microprocessor-controlled modules in the vehicle communicate with each other. Once the scan tool is connected to the class 2 serial data line through the DLC, the scan tool can be used to monitor each module for diagnostic purposes and to check for diagnostic trouble codes (DTCs). Class 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7.0 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a state of health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the inflatable restraint sensing and diagnostic module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. On some vehicles, if the PCM is unable to communicate with the VTD system after the vehicle has started, the PCM will consider the VTD system to be malfunctioning. The PCM will enter a fail enable state and will command the security indicator to illuminate. When the PCM is in a fail enable state the vehicle will NOT stall or stop running. If the PCM is in a fail enable state when the ignition is switched OFF, the PCM will remain fail enable until communications with the VTD system has been restored. When the PCM is in a fail enable state the VTD system is NOT active and the vehicle will start. This feature is NOT available on all GM vehicle lines. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16. - Scan tool power ground at terminal 4. - Class 2 serial data at terminal 2. - Common signal ground at terminal 5. CLASS 2 SERIAL DATA LINE The class 2 serial data line on this vehicle is a star configuration. The PCM has an additional class 2 serial data circuit to BCM or to theft deterrent control module, if equipped. If one of the class 2 serial data circuits to the PCM opens, communication will not be interrupted. The following modules communicate on the class 2 serial data line: The audio amplifier - The body control module (BCM) - The driver door module (DDM) - The electronic brake control module (EBCM) - The front passenger door control module (FPDM) - The HVAC control module - The inflatable restraint sensing and diagnostic module (SDM) - The instrument panel cluster (IPC) - The liftgate control module (LGM) - The memory seat module-driver, W/power seat - The memory seat module-passenger, W/power seat - The powertrain control module (PCM) - The radio - The RSA/HVAC control module-rear auxiliary - The theft deterrent control module, for export - The transfer case shift control module, W/4WD - The vehicle communication interface module (VCIM), W/UE1 The class 2 serial data line allows a scan tool to communicate with these modules for testing purposes, checking for DTCs, and to activate/enable/disable functions. These class 2 serial data circuits are bussed together via two splice packs and a data link connector (DLC): SP205 - Located behind the I/P near the headlamp switch connector. - SP306 - Located in the body harness near the rear of the right rear seat under the carpet. - DLC - Connects the scan tool to the class 2 serial data circuits. Refer to Data Link Communications Component Views. Page 209 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 427 Circuit/System Testing Component Testing Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 214 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 9277 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 4606 Fuel Injector: Diagrams Fuel Injector 1 Locations Memory/Heated Seat Switches Page 3074 1. Install the air cleaner element (1) onto the air outlet duct (2) with a twisting and pushing motion. 2. Snap the air cleaner element (1) and air outlet duct (3) into the lower air cleaner housing/washer solvent tank assembly (2). 3. Install the air cleaner cover/resonator assembly (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the three air cleaner cover/resonator retaining screws (2) one shown, to 4 N.m (35 lb in). 4. Install the radiator air intake baffle if applicable. 5. Install the radiator support diagonal brace if applicable. Page 12015 WA526F/72 - WA528F/76 Specifications Fluid Pan: Specifications Oil pan to transmission case bolt ......................................................................................................... ........................................................ 11 Nm (97 in.lb) Page 9537 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). A/T - Shift Lock Control Actuator Available Shift Interlock Solenoid: Technical Service Bulletins A/T - Shift Lock Control Actuator Available Bulletin No.: 05-07-129-001B Date: February 16, 2007 INFORMATION Subject: Automatic Transmission Shift Lock Control Actuator Available for Service Use Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2006 Chevrolet TrailBlazer EXT 2003-2006 Chevrolet SSR 2002-2007 GMC Envoy 2002-2006 GMC Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add the SSR. Please discard Corporate Bulletin Number 05-07-129-001A (Section 07 - Transmission/Transaxle). The automatic transmission shift lock control actuator is now available for service as a separate part. The actuator was formerly available only as part of the entire shifter assembly. DO NOT replace the shifter assembly if the shift lock control actuator requires replacement. Please refer to the Automatic Transmission Shift Lock Control Actuator Replacement procedure in the Automatic Transmission sub-section of the Service Information. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 7283 Abbreviations And Meanings Part 19 Page 5210 Band Apply Servo: Service and Repair 2-4 Servo Removal Procedure ^ Tools Required J 29714-A Servo Cover Depressor 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a suitable jack. 3. Remove the transmission support. 4. Remove the front exhaust pipe assembly. 5. Remove the heat shield if equipped. 6. Carefully lower the transmission to gain access to the 2-4 Servo. 7. Install the J29714-A. 8. Tighten the bolt in order to compress the servo cover. 9. Remove the servo cover retaining ring. 10. Remove the J 29714-A. Diagrams Transmission Range Switch Connector, Wiring Harness Side Page 13233 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 9693 Labor Time Information Page 3444 Page 4971 10. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Page 4675 On some 2004 model year Buick Rainier and GMC Envoy XUV; 2002-2004 model year Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles currently or previously registered in the corrosion areas shown above, the fuel tank modular reservoir assembly, which contains the fuel pump, may develop corrosion of the fuel feed/return pipes after an extended period of time. Severe corrosion may cause the formation of small perforations. These perforations may allow a small amount of fuel to accumulate in a recessed area outside of the fuel tank. If this were to occur, it would be accompanied by a fuel odor. If left uncorrected and the corrosion is allowed to progress, a fuel spray from the pipes may begin to occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to replace the fuel tank modular reservoir. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after September 30, 2008, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to September 30, 2008, must be submitted to the Service Contract provider. Vehicles Involved Page 10787 Lock Cylinder Switch: Description and Operation IGNITION LOCK CYLINDER CASE, INCLUDING THE PASSLOCK(TM) SENSOR The ignition lock cylinder fits inside the ignition lock cylinder case and operates the ignition switch when turned by a key with the proper mechanical cut. When the ignition key is used to turn the ignition lock cylinder to crank, start, a magnet on the lock cylinder passes close to the Passlock(TM) Sensor within the ignition lock cylinder case. The magnet activates the Security Hall Effect Sensor in the Passlock(TM) Sensor which completes a circuit from the security sensor signal circuit through a resistor to the security sensor low reference circuit. The resistance value will vary from vehicle to vehicle. If a magnet from outside of the ignition lock cylinder case is used to attempt to steal the vehicle, the Tamper Hall Effect Sensor will be activated. This completes a circuit from the security sensor signal circuit through a tamper resistor to the security sensor low reference circuit bypassing the security resistor. If the ignition switch is forced to rotate without the correct key, or if the ignition lock cylinder is removed by force, the Passlock(TM) Sensor will be damaged and will not operate. Page 5404 1. Install a new seal (2) into the transmission case. 2. Install the filler tube (1) into the seal. 3. Remove the drain pan. 4. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the nut (2) securing the filler tube to the exhaust manifold stud (1). ^ Tighten the nut to 10 Nm (89 inch lbs.). 6. Install the filler tube indicator. 7. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Page 10244 1. Position the VCIM bracket to the seat bracket. 2. Slide the VCIM bracket forward until the retaining tabs become locked to the seat bracket. 3. Ensure the retaining tab (1) on the VCIM bracket is properly seated. 4. Install the communication interface module. 5. Position the right second row seat to a passenger position. Page 37 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 9125 Page 4892 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 3463 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. A/T - 4L60-E, TCC Shudder/Water in Transmission Automatic Transmission Dipstick - Dipstick Tube: All Technical Service Bulletins A/T - 4L60-E, TCC Shudder/Water in Transmission Bulletin No.: 05-07-30-031 Date: November 11, 2005 TECHNICAL Subject: 4L60-E Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal) Models: 2004-2005 Buick Rainier 2003-2005 Chevrolet TrailBlazer Models 2003-2005 GMC Envoy Models 2003-2004 Oldsmobile Bravada 2005 Saab 9-7X with 4.2L In-Line 6 Cylinder Engine (VIN S - RPO LL8) Condition Some customers may comment on a shudder condition at approximately 64-80 km/h (40-50 mph) when the TCC engages. Cause This condition may be caused by water in the automatic transmission fluid (ATF). Water may enter the transmission by dripping from the cowl area onto the handle of the transmission fluid level indicator. Indications of water in the ATF may include: ^ Visible rust on the transmission fluid level indicator. ^ Visible water in the oil pan. ^ A milky white substance inside the pan area. ^ Spacer plate gaskets that appear to be glued to the spacer plate, valve body or case. ^ Rust on internal transmission iron/steel components. Important: For vehicles suspected of having a leaking transmission oil cooler that would cause contamination of the transmission fluid with coolant, the following check should be performed before deciding to replace the radiator. ^ Remove the surge tank cap and examine the coolant for signs of contamination with transmission fluid (the coolant will have a milky, not clear appearance). ^ If the coolant has a normal, clear appearance, the radiator should not be replaced. The cooler can also be tested by following the Coolant System Leak Test procedure in the SI Document. Do NOT replace a radiator without verifying that the transmission oil cooler is leaking. Correction First, repair the transmission and second, replace the transmission fill tube, seal and level indicator to prevent repeat water contamination of the ATF. Transmission Repair 1. Remove the transmission. Refer to the appropriate SI procedure. 2. Disassemble and inspect the transmission. Refer to Unit Repair Automatic Transmission 4L60-E/4L65-E. Important: Page 7150 Application Table Part 3 Page 2184 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 4. Connect the IP module yellow 4-way connector (1) located behind the IP support. 5. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. Page 12890 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 8128 8. Lower the Vehicle. Page 8636 Heater Hose: Service and Repair Heater Hose - Outlet With RPO Code LL8 HEATER HOSE REPLACEMENT - OUTLET (LL8) See: Application and ID/RPO Codes TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 2. Remove the transmission. 3. Remove the generator. 4. Using the J 43181 disconnect the outlet hose from the heater core outlet tube (1). 4.1. Install the J 43181 to the outlet heater core hose. 4.2. Close the tool around the outlet heater core hose. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the heater outlet hose (3) from the heater core (1). 6. Position the outlet heater hose clamp (6) at the water pump using J 38185. Page 6491 7. Install the park brake cable on the actuator. 8. Depress the retaining clips for the park brake cable. 9. Install the park brake retainer to the frame (left rear shown). Page 7254 Various symbols in order to describe different service operations. Page 6196 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 237 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 7055 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 13955 Abbreviations And Meanings Part 25 Page 9925 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 12066 WA812K/88 - WA813K/89 Page 9917 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 7314 Fuse: Application and ID Fuse Block - Rear (Long Wheelbase) Location View Page 9818 Abbreviations And Meanings Part 10 Page 5191 Installation Procedure 1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850. 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case. Page 13899 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 10877 Abbreviations And Meanings Part 13 Page 9877 7. Install the protective cover (1) to the module. 8. Position the right second row seat to a passenger position. 9. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 10. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 11. Use the ID information menu on the scan tool to access the new station ID (STID) and the electronic serial number (ESN) from the new VCIM. 12. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center and perform the following procedure: 12.1. Tell the advisor that this vehicle has received a new VCIM. 12.2. Ask the advisor to add the new STID and the ESN to update the customer's account. 12.3. Follow any additional instructions from the OnStar(R) advisor. 12.4. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Page 900 Door Control Module Diagram 3 Page 10519 Page 7268 Abbreviations And Meanings Part 4 Specifications Valve: Specifications Valve System Stationary Lash Adjuster Hydraulic Page 11056 1. Install the check link assembly through the door access hole. Ensure that the position arrow is pointing forward. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 2 check link retaining nuts to the door. Tighten the nuts to 7 N.m (62 lb in). 3. Install the rubber dust boot to the check link. 4. Install the 2 bolts that retain the check link to the pillar. Tighten the bolts to 15 N.m (11 lb ft). 5. Install and fully seat the water deflector. 6. Install the door trim panel. Page 7061 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 8698 fan noise can be expected with the updated PCM software calibrations. The last area of customer concern is the operation of the HVAC system blower motor. For vehicles equipped with automatic control HVAC systems (RPO CJ2), the blower motor fan speed will be limited to 80% of maximum when the HVAC system is operating in the automatic mode. To obtain maximum blower motor speed, instruct the customer to manually adjust the blower motor speed to the highest setting. Parts Information Warranty Information (excluding Saab U.S. Models) Disclaimer Engine Controls - Above Normal Temp. Gauge Readings PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12630 Seat Adjuster Switch - Passenger (w/o Heat) Part 2 Page 11642 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module yellow 4-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 1. Remove the key from the ignition. Page 7539 6. Connect the mobile telephone harness connector (1) to the junction block. 7. Connect the instrument panel harness connector (1) to the block base. 8. Install the junction block to the block base. Ensure that the retaining tabs are fully seated. Page 8285 Ambient Air Temperature Sensor Page 2547 8. Using a ratchet, rotate the threaded shaft of fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) in order to install the cylinder bore sleeve (117) into the engine block (100). 9. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch (1.6 mm) of the cylinder bore sleeve above the surface of the cylinder block. 10. Using a torque wrench, torque the threaded shaft of the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly to 102 N.m (75 lb ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore sleeve flange will protrude above the block deck surface. 11. Remove the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) from the cylinder block (100). Cylinder Sleeve Trimming ^ EN 45680-865 Debris Collector (3) ^ EN 45680-411 Trim Tool Assembly (2) ^ Air Control Valve (1 - Part of EN 45680-411 Diagram Information and Instructions Door Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 2808 Abbreviations And Meanings Part 6 Page 13003 Abbreviations And Meanings Part 4 Page 9717 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 13895 Page 6669 Conversion - English/Metric Part 1 Page 7397 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6343 6. Remove the front brake pads from the mounting bracket. 7. Inspect the brake hardware. 8. Remove the brake pad retaining clips from the mounting bracket. 9. Remove the brake caliper mounting bracket retaining bolts. Page 12233 Memory Seat Module - Passenger C2 Page 1701 Page 13715 Door Switch: Diagrams Miniwedge (Door Jamb Switch) - LF Page 13887 Page 350 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 6233 Registered And Non-Registered Trademarks Part 6 Page 9792 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 3030 Important: The engine front cover must be installed within 10 minutes from when the sealer was applied. 2. Apply a 3 mm (0.12 inch) bead of sealer GM P/N 12378521 to the trace grooves on back side of the engine front cover (1). 3. Also apply sealant on the inside three bolt hole bosses on the cover. 4. Align the oil pump to the crankshaft sprocket splines. 5. Install the front cover. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 6. Install the front cover bolts, tightening the center bolt last (1). Tighten the front cover bolts to 10 Nm (89 inch lbs.). 7. Remove the J44219. 8. Raise the vehicle. Refer to Vehicle Lifting. 9. Install the oil pan. 10. Lower the vehicle. 11. Install the power steering pump. 12. Install the crankshaft balancer. 13. Install the water pump. 14. Install the drivebelt. 15. Install the cooling fan and shroud. 16. Fill the engine with coolant. Page 4450 Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). Page 6010 Automatic Transmission Shift Lock Control Solenoid Page 2941 Abbreviations And Meanings Part 13 Locations Trailer Connector Page 2051 2. Reposition the inlet radiator hose clamp at the thermostat (1) using J 38185. 3. Remove the inlet radiator hose from the thermostat. 4. Raise the vehicle. Refer to Vehicle Lifting. See: Engine, Cooling and Exhaust/Service Precautions/Technician Safety Information/Vehicle Lifting Caution 5. Remove the lower radiator support shield, if equipped. 6. Reposition the inlet radiator hose clamp at the radiator using J 38185. 7. Remove the inlet radiator hose (1) from the radiator. Installation Procedure 1. Install the inlet radiator hose clamps to the radiator hose (1). 2. Install the inlet radiator hose (1) to the radiator. 3. Reposition the inlet radiator hose clamp using J 38185. Page 4473 Variable Valve Timing Solenoid: Service and Repair CAMSHAFT POSITION (CMP) ACTUATOR SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the drive belt. 2. Remove the 3 power steering pump bolts and move the pump out of the way. 3. Disconnect the camshaft position actuator solenoid electrical connector. 4. Remove the camshaft position actuator solenoid retaining bolt (3). 5. Remove the camshaft position actuator solenoid (2) from the engine block. 6. Clean debris from the hole (1). INSTALLATION PROCEDURE 1. Install a new O-ring on the camshaft position actuator solenoid. 2. Lubricate the hole (1) with engine oil. 3. Install the camshaft position actuator solenoid (2) and bolt (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Connect the camshaft position actuator solenoid electrical connector. 5. Install the power steering pump and bolts. 6. Install the drive belt. Page 9122 Specifications Wheel Bearing: Specifications Wheel Hub and Bearing Mounting Bolts 77 ft. lbs. Page 5916 Disclaimer Page 10196 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 1730 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 57 Abbreviations And Meanings Part 2 Page 12017 WA5322/33 - WA534F/54 Page 8044 - For vehicles with dual rear wheels (different tire sizes and load ranges), rotate the tires as shown. - For vehicles with dual rear wheels (including the spare tire), rotate the tires as shown. Page 2173 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the LF door trim panel. 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. Page 6688 Abbreviations And Meanings Part 10 Page 6670 Conversion - English/Metric Part 2 Page 10426 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 12530 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 5338 8. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 13115 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 12021 WA722J/25 - WA765J/37 Page 8742 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 10324 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 13101 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Engine - Broken Bolt Extraction Information Crankshaft Main Bearing: Technical Service Bulletins Engine - Broken Bolt Extraction Information INFORMATION Bulletin No.: 05-06-01-026B Date: October 21, 2008 Subject: Information On Torque to Yield Bolt Breakage and Use of Bolt Extractor Tool Kit Part Number EN-47702 for Removing Broken Cylinder Head or Main Bearing Cap Bolts on Inline Truck Engines Models: 2004-2007 Buick Rainier 2002-2009 Chevrolet TrailBlazer 2004-2009 Chevrolet Colorado 2002-2009 GMC Envoy 2004-2009 GMC Canyon 2002-2004 Oldsmobile Bravada 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with 2.8L, 2.9L, 3.5L, 3.7L or 4.2L Vortec Inline Engine (VINs 8, 9, 6, E, S - RPOs LK5, LLV, L52, LLR, LL8) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-06-01-026A (Section 06 - Engine/Propulsion System). A Torque To Yield (TTY) bolt, like a cylinder head bolt or main bearing cap bolt, may break during repair procedures. Interaction between a TTY bolt and threads may cause the bolt to bind or break on removal. Prior to removing the cylinder head or main cap bolts, perform the following procedure: Using an appropriately sized punch and hammer, rap on the head of each bolt. The vibration produced by this procedure will assist in successful removal. If a head bolt or main bolt breaks during engine disassembly, a broken bolt extractor kit (EN-47702) has been released to assist in removal of the remaining bolt segment. Many times the remaining bolt segment will back out easily with a pick tool or a reverse twist drill bit. Bolt Replacement & Tightening Important: Never reuse TTY main bearing or cylinder head bolts. Always make sure that the engine block threaded holes are clean and do not place oil or threadlocker on the bolts. Utilize a thread chase tool followed by cleaning with dry compressed air to insure threads are clean and dry prior to installation of new TTY bolts. Bolts that creak and snap while tightening will fail due to excessive torque caused by threads contaminated with debris, antifreeze or oil. Trace amounts of oil or antifreeze will cause this condition. In extreme cases the threads may need additional cleaning with a non-residue cleaner like a brake clean product followed by drying with clean & dry compressed air. Fuse Block - Rear (Short Wheelbase) Fuse: Application and ID Fuse Block - Rear (Short Wheelbase) Location View Page 12778 Page 4249 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 4469 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 3598 Accelerator Pedal Position (APP) Sensor Page 3460 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 7850 Installation Procedure 1. Install the lower control arm. 2. Install the rear axle lower control arm to the frame mounting nut and bolt. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear axle lower control arm to the axle mounting bolt and nut. Tighten the lower control arm mounting bolts to 100 Nm (74 ft. lbs.). 4. Remove the rear axle support. 5. Lower the vehicle. Page 2070 Coolant: Description and Operation Cooling System The cooling system's function is to maintain an efficient engine operating temperature during all engine speeds and operating conditions. The cooling system is designed to remove approximately 1/3 of the heat produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not flow to the radiator until the thermostat opens. This allows the engine to warm quickly. Cooling Cycle Coolant is drawn from the radiator outlet and into the water pump inlet by the water pump. Coolant will then be pumped through the water pump outlet and into the engine block. In the engine block, the coolant circulates through the water jackets surrounding the cylinders, where the coolant absorbs heat. Some coolant is also pumped from the water pump to the heater core, then back to the water pump. This provides the passenger compartment with heat and defrost. The coolant is then forced through the cylinder head gasket openings and into the cylinder heads. In the cylinder heads, the coolant flows through the water jackets surrounding the combustion chambers and valve seats, where the coolant absorbs additional heat. Coolant is also directed to the throttle body. There the coolant circulates through passages in the casting. During initial start up, the coolant assists in warming the throttle body. During normal operating temperatures, the coolant assists in keeping the throttle body cool. From the cylinder heads, the coolant is then forced to the thermostat. The flow of coolant will either be stopped at the thermostat until the engine is warmed, or the coolant will flow through the thermostat and into the radiator where the coolant is cooled and the coolant cycle is completed. Operation of the cooling system requires proper functioning of all cooling system components. The cooling system consists of the following components, which are described below: - The coolant - The radiator - The pressure cap - The coolant recovery system - The air baffles and seals Coolant The engine coolant is a solution made up of a 50-50 mixture of DEX-COOL and suitable drinking water. The coolant solution carries excess heat away from the engine to the radiator, where the heat is dissipated to the atmosphere. Page 6212 Abbreviations And Meanings Part 11 Page 9843 Garage Door Opener Transmitter: Electrical Diagrams Garage Door Opener Diagram Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 9530 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 2809 Abbreviations And Meanings Part 7 Page 883 Registered And Non-Registered Trademarks Part 2 Locations Page 10148 Page 14009 Page 7350 Fuse Block - Underhood C2 Part 1 Page 3492 Abbreviations And Meanings Part 9 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 13188 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 4. Install the LF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Page 2953 Abbreviations And Meanings Part 25 Page 12361 Memory Seat Module - Passenger C1 A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 13134 Abbreviations And Meanings Part 6 Page 6310 Brake Rotor/Disc: Service and Repair Disc Brake Backing Plate Replacement - Rear Disc Brake Backing Plate Replacement- Rear Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the park brake cable from the rear brake caliper. 4. Remove the brake caliper and bracket assembly. 5. Remove the rear brake rotor. Page 7255 Conversion - English/Metric Part 1 Page 1409 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor (1) from the air duct with a twisting and pulling motion. INSTALLATION PROCEDURE 1. Install the IAT sensor (1) to the air duct with a pushing and twisting motion. 2. Reconnect the IAT sensor electrical connector. Page 671 Memory Seat Module - Passenger C4 Part 3 Specifications Wheel Hub: Specifications Wheel Hub and Bearing Mounting Bolts 77 ft. lbs. Wheel Hub Bolt 95 ft. lbs. Wheel Speed Sensor to the Wheel Hub and Bearing Mounting Bolt 13 ft. lbs. Page 6113 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the electrical connectors from the EBCM (2). 2. Remove the four T 25-TORXmounting screws (1) that fasten the EBCM (2) to the BPMV (3). 3. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not use a tool to pry the EBCM or the BPMV. 4. Clean the BPMV (3) to EBCM (2) mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) on to the BPMV (3). Page 1161 Quarterglass Switch - R Page 826 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 2789 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 8787 For vehicles repaired under warranty, use the table. Disclaimer Page 619 Registered And Non-Registered Trademarks Part 5 Page 458 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 10486 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 9488 Page 10448 Disclaimer Page 12957 Page 8456 12. Connect the compressor discharge hose (2) to the condenser. 13. Install the compressor discharge hose nut (1) to the condenser. Tighten Tighten the nut to 16 Nm (12 lb ft). 14. Evacuate and recharge the A/C system. 15. Leak test the fittings of the components using J 39400-A . Page 13147 Abbreviations And Meanings Part 19 Page 12857 Audible Warning Device: Electrical Diagrams Audible Warnings Diagram Page 6582 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. 1. Raise the vehicle. 2. Remove tire and wheel. 3. Remove brake caliper. 4. Remove the hub and rotor. 5. Remove wheel speed sensor mounting clip on the control arm. 6. Remove wheel speed sensor mounting clip on the frame rail. 7. Disconnect the wheel speed sensor electrical connector (2). 8. Remove the sensor mounting screw (5). Important: The wheel speed sensor mounts into a bore that leads to the center of the sealed bearing. Use caution when cleaning or working around the bore. Do not contaminate the lubricant inside the sealed bearing. Failure to do so can lead to premature bearing failure. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device. Prying will cause the sensor body to break off in the bore. Notice: Do not attempt to remove the stainless steel shim from the bearing assembly. The shim is permanently attached. If the shim is damaged or bent, replace the bearing assembly. Failure to comply will result in diminished sensor and ABS performance. 9. Remove wheel speed sensor from hub and bearing assembly. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The new speed sensor will have a new O-ring. Dispose of the old O-ring. Lubricate the new O-ring lightly with bearing grease prior to installation. You may also lubricate the sensor just above and below the new O-ring. DO NOT lubricate the bore. Page 6273 3. Ensure that the brake pad retaining clip in the brake caliper is properly seated. 4. Install the inboard brake pad. 5. Install the outboard brake pad. 6. Rotate the brake caliper down into position. Page 6823 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 2674 Engine Mount: Testing and Inspection Engine Mount Inspection Front Engine Mount Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Install a pole jack underneath the oil pan. 2. Insert a block of wood between the engine oil pan and the pole jack. 3. Raise the jack until the wooden block contacts the engine oil pan. 4. Raise the engine in order to place a slight tension on the rubber cushion. Observe both mounts while raising the engine. 5. Replace the mounts if any of the following conditions exist: - Hard rubber surface covered with heat check cracks - The rubber cushion separated from the metal plate of the mount - The rubber cushion is split through the center 6. If there is movement between a metal plate of the mount and its attaching points, lower the engine and tighten the bolts or nuts attaching the mount to the engine, the frame or the bracket. Page 9445 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 9382 Abbreviations And Meanings Part 16 Page 8199 Instrument Panel Carrier, Cowl Side Lower Console (w/Automatic - HVAC System) (Body Type VIN 6) Page 3713 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. 1. Install the CKP sensor into the engine block. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 629 Front Passenger Door Module (FPDM) - C1 Page 7289 Abbreviations And Meanings Part 25 Page 11891 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. 3. Install the actuator to the top of the latch. IMPORTANT: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 4. Install the 2 screws that retain the actuator (1) to the lock. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Page 6969 Fuse Block - Underhood C1 Part 5 Page 3859 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor (1) from the air duct with a twisting and pulling motion. INSTALLATION PROCEDURE 1. Install the IAT sensor (1) to the air duct with a pushing and twisting motion. 2. Reconnect the IAT sensor electrical connector. Diagrams Trunk / Liftgate Switch: Diagrams Liftgate Ajar Switch Page 11780 Page 5367 Disclaimer Page 7858 1. Install the transmission support to the frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper transmission support to the frame mounting bolts. Tighten the upper transmission support to the frame mounting bolts to 80 N.m (59 lb ft). 3. Install the lower transmission support to the frame mounting bolts. Tighten the bolts to 50 N.m (37 lb ft). 4. Lower the transmission onto the transmission support. 5. Install the transmission mount to the transmission support retaining nuts. Tighten the transmission mount to the transmission support retaining nuts to 46 N.m (35 lb ft). 6. Install the evaporative emission (EVAP) canister. 7. Install the fuel tank shield. 8. Lower the vehicle. Air Deflector Replacement - Front Bumper Fascia Air Dam: Service and Repair Air Deflector Replacement - Front Bumper Fascia Air Deflector Replacement - Front Bumper Fascia Removal Procedure 1. Release the tabs that retain the air deflector to the fascia. 2. Remove the push-pin retaining the air deflector to the fascia. 3. Remove the air deflector from the fascia. Installation Procedure 1. Install the air deflector to the fascia. 2. Install the push-pin that retains the air deflector to the fascia. 3. Install and fully seat the tabs that retain the air deflector to the fascia. Page 4099 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 13001 Abbreviations And Meanings Part 2 Page 107 Alarm Module: Description and Operation THEFT DETERRENT CONTROL MODULE Vehicles with steering column mounted ignition switches have the exciter integral with the theft deterrent control module which is located within the steering column. Vehicles with instrument panel mounted ignition switches have exciter modules separate from the theft deterrent control module with the vehicle wiring harness connecting the two. The theft deterrent control module for vehicles with instrument panel mounted ignition switches is located within the instrument panel. The theft deterrent control module can learn up to ten keys (transponder values). The theft deterrent control module uses the following inputs, battery voltage, ignition switched voltage and ground circuit. The theft deterrent control module uses the following outputs, password exchange with the PCM, fuel enable/disable via the serial data circuit. When an ignition key is inserted into the ignition lock cylinder and the ignition is switched ON, the transponder embedded in the head of the key is energized by the exciter coils surrounding the ignition lock cylinder. The energized transponder transmits a signal that contains its unique value, which is received by the theft deterrent control module. The theft deterrent control module then compares this value to a value stored in memory, learned key code. If the value is correct the theft deterrent control module sends a random generated number to the transponder, this is called a challenge. Both the transponder and the theft deterrent control module perform a calculation on the challenge. The theft deterrent control module then performs one of the following functions: - If both the transponder value and the calculation to the challenge are correct, the theft deterrent control module will send the fuel continue password to the PCM via the serial data circuit. - If either the transponders unique value or the calculation to the challenge is incorrect the theft deterrent control module will send the fuel disable password to the PCM via the serial data circuit. - If the theft deterrent control module is unable to measure the ignition key transponder value for one second due to a damaged or missing pellet or a damaged exciter, the theft deterrent control module will send the fuel disable password to the PCM via the serial data circuit. Page 5352 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Page 5180 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector.Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON transmission fluid. Page 12846 Abbreviations And Meanings Part 23 Page 6794 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 4309 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Page 8948 5. Loosen the bolts (1) retaining the sensor to the frame. 6. Remove the sensor assembly from the frame (1). 7. Position the sensor assembly above the front bumper. 8. Remove the retaining bolts and protective cover (1) from the sensor. 9. Remove the connector-position assurance (CPA) from the sensor electrical connector. 10. Disconnect the sensor (2) electrical connector. 11. Remove the sensor from the vehicle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Page 10018 Page 7344 Fuse Block - Rear C4 Part 4 Fuse Block - Underhood C1 Fuse Block - Underhood C1 Part 1 Page 10378 Registered And Non-Registered Trademarks Part 5 Fuel System - Fuel Spit-Back/Early Pump Nozzle Shut-Off Fuel Filler Hose: Customer Interest Fuel System - Fuel Spit-Back/Early Pump Nozzle Shut-Off Bulletin No.: 04-06-04-003A Date: August 11, 2004 TECHNICAL Subject: Vehicle is Difficult to Fill with Fuel or Filling Station Pump Shuts Off Before Tank is Full or Fuel Spits Back/Out When Filling Tank (Replace Fuel Tank Filler Upper Pipe and Lower Hose) Models: 2003 Chevrolet TrailBlazer with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2003 GMC Envoy with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2003 Oldsmobile Bravada with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL 2004 Buick Rainier 2004 Chevrolet TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Envoy XUV 2004 Oldsmobile Bravada Built Prior to December 2003 Supercede: This bulletin is being revised to provide new part number for 2002-2003 vehicles. Please discard Corporate Bulletin Number 04-06-04-003 (Section 06 - Engine/Propulsion System). This bulletin provides information on two different conditions. Condition 1 Some customers may comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. Cause This condition may be caused by the variability (fuel flow rates, type of fuel fill nozzle, fuel properties) at the filling stations. There is a potential to develop an increase in back pressures internal to the fuel fill neck. This back pressure trips the fuel nozzle prior to filling the tank, or results in a hard to fill condition. Condition 2 Some customers may comment that when filling the fuel tank, a small amount of fuel may spit back/out. Cause This condition may be caused by the equalization of pressure between the fuel tank and the fuel fill neck that does not react quickly to the variance in the pressure when the fueling station fuel nozzle trips off. Correction Replace the fuel tank filler upper pipe assembly with P/N 88983256 or P/N 15131043, and lower hose assembly with P/N 15131046. The new upper pipe has been redesigned to provide smoother flow conditions within the section and the lower hose has been redesigned to include a checking feature. Use the procedure listed below. 1. Remove the fuel fill cap. 2. Remove the fuel fill pipe housing. Page 7917 5. Disconnect the air spring compressor electrical connection (2). Important: Ensure the color on air supply lines match the color on the air spring compressor for reassembly. 6. Disconnect the air supply lines (3) from the air spring compressor (1). 7. Remove the air spring compressor from the vehicle. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: Check the air supply lines for deep scores or cuts. If the air supply lines are damage the lines must be replaced. 1. If no damage to the air supply pipes is evident, then remove the fittings from the new compressor and use existing fittings that are already attached to air supply lines. Install the air supply lines with existing fittings to the air spring compressor. Tighten the air supply line fittings to 2.25 Nm (18.5 lb in). 2. If damage is evident to the air supply lines, then replace the air supply lines. Page 4041 Powertrain Control Module (PCM) C2 Part 3 Page 2174 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Access IP module connector through glove box. 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 7986 2. Turn the spring compressor forcing screw (1) until the coil spring is compressed. 3. Install the shock absorber to the shock module. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the shock absorber retaining nut. Tighten the shock absorber retaining nut to 45 Nm (33 ft. lbs.). 5. Remove the shock module (2) from the J45400 (1) 6. Remove the pieces of heater hose from the shock module spring. Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 11807 Conversion - English/Metric Part 2 Page 4805 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 3947 Body Control Module: Connector Views Body Control Module (BCM) C1 Part 1 Page 10004 Page 10252 Audio Amplifier C2 (With RPO Code UQA) Part 2 Page 4055 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ....................................... 334 - 375 kPa (48 - 54 PSI) Fuel Pressure Drop (After 1 minute) ............................................................................................................................................................. 34 kPa (5 PSI) Page 11666 16. Remove the rear seats. 17. Remove the headliner harness retaining clips (2) from the rocker panel and floor panel. 18. Remove the center pillar headliner harness electrical connector from the bussed electrical center, and the block base from the floor panel. 19. Reach underneath the carpet and remove the headliner harness electrical connector (1) from the IP wire harness. 20. Disconnect the inside rear view mirror electrical connector (6). 21. Disconnect the rain sensor electrical connector, if equipped. 22. Disconnect the navigation antenna electrical connector, if equipped. 23. Remove the upper rear quarter trim panels. 24. Remove the coat hooks from the roof panel. 25. Disconnect the electrical connector from the cellular phone antenna. 26. Remove the 2 push pins from the rear of the headliner. 27. Release the assist handles from the roof panel. Refer to Assist Handle Replacement. 28. Fully recline the bucket seats. 29. With the aid of an assistant, release the interlocking strips (1) that retain the headliner to the roof panel. 30. If the vehicle is equipped with a sunroof, partially lower the headliner and disconnect the sunroof assembly electrical connector. 31. With the aid of an assistant, remove the headliner from the vehicle. Installation Procedure 1. With the aid of an assistant, install the headliner into the vehicle. Page 4497 Canister Vent Valve: Description and Operation EVAP VENT SOLENOID The EVAP vent solenoid controls fresh airflow into the EVAP canister. The solenoid is normally open. The control module will command the solenoid closed during some EVAP tests, allowing the system to be tested for leaks. Page 1185 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. 1. Raise the vehicle. 2. Remove tire and wheel. 3. Remove brake caliper. 4. Remove the hub and rotor. 5. Remove wheel speed sensor mounting clip on the control arm. 6. Remove wheel speed sensor mounting clip on the frame rail. 7. Disconnect the wheel speed sensor electrical connector (2). 8. Remove the sensor mounting screw (5). Important: The wheel speed sensor mounts into a bore that leads to the center of the sealed bearing. Use caution when cleaning or working around the bore. Do not contaminate the lubricant inside the sealed bearing. Failure to do so can lead to premature bearing failure. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device. Prying will cause the sensor body to break off in the bore. Notice: Do not attempt to remove the stainless steel shim from the bearing assembly. The shim is permanently attached. If the shim is damaged or bent, replace the bearing assembly. Failure to comply will result in diminished sensor and ABS performance. 9. Remove wheel speed sensor from hub and bearing assembly. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The new speed sensor will have a new O-ring. Dispose of the old O-ring. Lubricate the new O-ring lightly with bearing grease prior to installation. You may also lubricate the sensor just above and below the new O-ring. DO NOT lubricate the bore. Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement - Front (Chevrolet (X88) ONLY) Removal Procedure 1. Remove the grille 2. Remove the front fascia. 3. Remove the front impact bar. 4. Place the impact bar on a clean, prepared surface. 5. Remove the bolt that retains the tow hook to the impact bar. 6. Remove the tow hook from the impact bar. Installation Procedure 1. Install the tow hook to the impact bar, ensuring that the locating pin is properly indexed to the impact bar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt which retains the tow hook to the impact bar. Tighten the bolt to 50 N.m (37 lb ft). 3. Install the impact bar. 4. Install the fascia. 5. Install the grille. Page 6335 Brake Caliper: Technical Service Bulletins Brakes - Rear Caliper Mounting Bolt Torque Revision Bulletin No.: 04-05-23-003 Date: April 22, 2004 SERVICE MANUAL UPDATE Subject: Revised Rear Brake Caliper Bracket Mounting Bolt Fastener Specification Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2004 Isuzu Ascender This bulletin is being issued to revise the fastener tightening specification for the rear brake caliper bracket mounting bolt in the Disc Brakes sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The revised specification is as follows: Rear Brake Caliper Bracket Mounting Bolt - 200 N.m (147 lb ft) Disclaimer Page 9058 1. Position the center seat belt anchor to the seat belt buckle and anchor plate assembly. IMPORTANT: When installing the center seat belt anchor to the seat belt buckle/anchor plate assembly, ensure that the center seat belt webbing is not twisted. - Ensure that the center seat belt anchor is properly indexed between the locating tangs on the seat belt buckle/anchor plate assembly. 1. Install the center seat belt anchor bolt that retains the center seat belt anchor to the seat belt buckle/anchor plate assembly. Tighten the bolt finger tight. NOTE: Refer to Fastener Notice in Service Precautions. 2. Position the seat belt buckle/anchor plate assembly to the rear seat back hinge bracket. 3. Install the left rear seat back rear mounting nut that retains the left seat back to the floor panel. Tighten Tighten the rear seat back rear mounting nut to 45 N.m (33 lb ft). - Tighten the center seat belt anchor bolt to 50 N.m (37 lb ft). 1. Return the rear seats to the passenger position. Side Buckle Replacement - Rear (TrailBlazer EXT, Envoy XL) REMOVAL PROCEDURE 1. Remove the 3 screws securing the inboard rear seat back hinge cover. Interior - Proper Use of Floor Mats Carpet: All Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Page 4129 Abbreviations And Meanings Part 15 Page 8988 Inflatable Restraint Sensing And Diagnostic Module: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Diagrams Hood Ajar Switch (Export) Page 9299 Steering Column Page 3872 Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 10485 Page 7069 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 4172 Steps 17-19 Locations Fuel Tank Pressure Sensor: Locations Fuel Tank Page 3484 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 832 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 9364 English Prevailing Torque Fastener Minimum Torque Development Part 1 A/C - Intermittently Inoperative/Poor Performance Control Module HVAC: All Technical Service Bulletins A/C - Intermittently Inoperative/Poor Performance Bulletin No.: 02-01-39-005A Date: August 17, 2005 TECHNICAL Subject: HVAC System Inoperative For A Drive Cycle, Poor HVAC System Performance In High Ambient Temperatures (Update HVAC Control Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to correct the RPO usage information below: RPO CJ2 = HVAC System Air Conditioner Front, Automatic Temperature Control, Auxiliary Temperature Control RPO CJ3 = HVAC System Air Conditioner Front, Manual Temperature Control, Auxiliary Temperature Control Please discard Corporate Bulletin Number 02-01-39-005 (Section 01 - HVAC). Condition Some customers may comment about no cold air from the heating, ventilation and air conditioning (HVAC) system during a drive cycle. This concern may occur at any time during the drive cycle and at any temperature setting. The HVAC system operation returns to normal after the vehicle has been keyed to off and restarted. This concern is intermittent and most likely to occur on hot days. This concern may be found on vehicles equipped with manual (CJ3) and automatic (CJ2) HVAC systems. Other customers may comment about poor HVAC system performance in high ambient temperature conditions. This concern may be present in automatic (CJ2) HVAC systems only. An HVAC control module software update was put into all production vehicles beginning in September 2002. Vehicles built in September 2002 and earlier may need this software update. Correction Update the HVAC control module using software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. This software update addresses both the intermittent no cooling and the poor performance concerns. If the software update does not correct the concerns, perform the HVAC Diagnostic System Check and repair as necessary. If the HVAC control module is replaced with a part from GMSPO, make sure the module has the latest software update. The module may need to be updated even though it is a new part. Warranty Information Disclaimer Page 8392 Abbreviations And Meanings Part 12 Page 2997 Oil Pressure Sensor: Diagrams Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Page 12141 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 33 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 12828 Abbreviations And Meanings Part 5 Page 4566 1. Install the air cleaner element (1) onto the air outlet duct (2) with a twisting and pushing motion. 2. Snap the air cleaner element (1) and air outlet duct (3) into the lower air cleaner housing/washer solvent tank assembly (2). 3. Install the air cleaner cover/resonator assembly (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the three air cleaner cover/resonator retaining screws (2) one shown, to 4 N.m (35 lb in). 4. Install the radiator air intake baffle if applicable. 5. Install the radiator support diagonal brace if applicable. Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 418 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 2794 Conversion - English/Metric Part 2 Page 676 Liftgate Module (LGM) C2 (Except XUV) Page 3938 Abbreviations And Meanings Part 25 Page 5145 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Diagrams Windshield Wiper/Washer Switch (Turn Signal/Multifunction Switch C3) Locations Engine, Right Front Page 4114 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Powertrain Control Module (PCM) C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Powertrain Control Module (PCM) C1 Part 1 Page 13236 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 12702 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6195 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 4081 Information Bus: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 9367 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 2201 Application Table Part 3 Location View Page 4564 Disclaimer Page 4970 3. Install the 1-2 and 2-3 Shift solenoids. 4. Install the 1-2 and 2-3 Shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. Page 2582 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement Special Tools - Insert new tool J 44226-1 Crankshaft Balancer Remover/Holder - EN-48034 Harmonic Balancer Installer - J 41816-A Crankshaft Balancer Remover - J 41816-2 Crankshaft End Protector - J 45059 Torque Angle Meter Removal Procedure 1. Remove the radiator. 2. Remove the drive belt. Important: When removing the diagonal brace, only remove the one bolt from the battery tray brace that is bolted to the radiator brace. 3. Carefully loosen and remove the balancer bolt. Discard the bolt. 4. Remove the service slot plug. 5. Lower the vehicle. Page 7347 Fuse Block - Underhood C1 Part 4 OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 846 Conversion - English/Metric Part 1 Page 4241 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 2559 Note: Do not use any air powered or electric tools to rotate the threaded shaft of the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly or damage to the cylinder bore sleeve will occur. 8. Using a ratchet, rotate the threaded shaft of fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) in order to install the cylinder bore sleeve (117) into the engine block (100). 9. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch (1.6 mm) of the cylinder bore sleeve above the surface of the cylinder block. 10. Using a torque wrench, torque the threaded shaft of the fixture EN 45680-401/cylinder bore sleeve installer EN assembly to 102 Nm (75 lb ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore sleeve flange will protrude above the block deck surface. Locations Lock Cylinder Switch: Locations Ignition Switch Page 11904 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. Installation Procedure 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. Important: When replacing the passenger door module, the set up procedure must be performed. 4. If replacing the passenger door module, program the passenger door module. Refer to Service Programming System (SPS) (Remote Procedure) Service Programming System (SPS) (Pass-Thru Procedure) Service Programming System (SPS) (Off Board Remote Procedure) Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 5113 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 3177 34. Install the coolant bypass valve to its original location and secure with a nut. 35. Connect the other end of the new hose from step 29 to the outlet port of the auxiliary heater pump. 36. Connect the vacuum hose to the coolant bypass valve. 37. Connect the coolant bypass valve hose to the auxiliary rear heater line. 38. Install the heater hose quick connect retainers to the heater core pipes. 39. Connect the remaining two hoses to the heater core. 40. Install the new auxiliary heater pump wiring harness to the vehicle. Page 5114 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 10127 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 2968 1. Use the J 44227 to install the crankshaft rear oil seal. 2. Remove the J 44227. 3. Apply a 3 mm (0.12 inch) bead of GM P/N 12378521 to the rear oil seal housing (1). 4. Install the J 44219 guide pins into the block. Important: When installing a new seal, use the plastic installation sleeve supplied with the new seal. The seal installation sleeve should come off after the seal is installed. Disregard the sleeve. 5. Slide the crankshaft rear oil seal housing over the alignment pins J 44219 and crankshaft. 6. Install the crankshaft rear oil seal housing bolts, except the two in place of the guide pins. 7. Remove the J 44219 guide pins. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 8. Install the remaining two crankshaft rear oil seal housing bolts. Tighten all the oil seal housing bolts to 10 Nm (89 inch lbs.). Page 5942 Electronic Components Page 1743 Abbreviations And Meanings Part 7 Page 12823 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 10171 Page 7331 Fuse Block - Rear C1 Part 5 Page 10025 Page 12663 Quarterglass Switch - R Page 6852 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 13239 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 8921 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 3 Page 12023 WA800J/98 - WA805K/62 Page 2234 Fuse Block - Underhood C2 Part 1 Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 10162 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Page 13714 Lifgate Ajar Switch Camshaft Actuator System Camshaft Position Sensor: Description and Operation Camshaft Actuator System CAMSHAFT POSITION (CMP) ACTUATOR SYSTEM The Camshaft Position Actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation control, a wider engine torque range, improved gas millage, and improved engine idle stability. The CMP Actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. CMP ACTUATOR SYSTEM OPERATION The CMP Actuator system is controlled by the Powertrain Control Module (PCM). The PCM sends a pulse width modulated 12 volt signal to a Camshaft Position (CMP) Actuator Solenoid in order to control the amount of engine oil flow to a cam Phaser passage. There are two different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The Cam Phaser is attached to a camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position. Engine oil pressure, viscosity, temperature and engine oil level can have an adverse affect on cam phaser performance. The PCM calculates the optimum cam position through the following inputs: Engine Speed - Manifold Absolute Pressure (MAP) - Throttle Position (TP) Indicated Angle - Crankshaft Position (CKP) - Camshaft Position (CMP) - Engine Load. - Barometric (BARO) Pressure The Cam Phaser default position is 0 degrees. The PCM uses the following inputs before assuming control of the cam phaser: Engine Coolant Temperature (ECT) - Closed Loop Fuel Control - Engine Oil Temperature - Engine Oil Pressure - Engine Oil Level - CMP Actuator Solenoid circuit state - Ignition 1 signal voltage - Barometric (BARO) Pressure CMP ACTUATOR SOLENOID CIRCUIT DIAGNOSTICS The PCM monitors the control circuits of the CMP Actuator Solenoid for electrical faults. The PCM has the ability to determine if a control circuit is open, shorted high, and shorted low. If the PCM detects a fault with a CMP Actuator Solenoid circuit a Diagnostic Trouble Code (DTC) will set. CMP ACTUATOR SYSTEM PERFORMANCE DIAGNOSTICS The PCM monitors the performance of the CMP Actuator system by monitoring the actual and desired positions of a cam phaser. If the difference between the actual and desired position is more than a calibrated angle for more than a calibrated amount of time, a DTC will set. Service and Repair Parking Light Bulb: Service and Repair PARK/TURN SIGNAL/SIDE MARKER LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Rotate the bulb and socket counterclockwise in order to remove the bulb and socket from the housing. 3. Remove the side marker bulb (4) or turn signal/park bulb (3) from the socket. INSTALLATION PROCEDURE 1. Install the side marker bulb (4) or turn signal/park bulb (3) to the socket. 2. Wipe the bulb with a clean cloth to ensure the bulb is free of any dirt or oil. 3. Install the bulb and socket to the headlamp by rotating the bulb and socket clockwise, locking the retaining tabs to the headlamp. 4. Close the hood. Page 7608 Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Page 6867 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Service and Repair Sunroof / Moonroof Panel: Service and Repair SUNROOF WINDOW REPLACEMENT REMOVAL PROCEDURE 1. Open the sunshade panel. IMPORTANT: The sunroof must be in the fully closed position prior to removing the sunroof window. 2. Remove the 4 screws (2) that retain the sunroof window (1) to the sunroof module assembly. 3. Remove the sunroof window from the top of the vehicle. INSTALLATION PROCEDURE 1. Position the sunroof window (1) to the vehicle. 2. Install the screws (2) that retain the sunroof window (1) to the sunroof module assembly. 3. Adjust the sunroof window height so that the window is flush with the roof panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 3 N.m (27 lb in). Service and Repair Front Fender Liner: Service and Repair Wheelhouse Panel Replacement Removal Procedure 1. Remove the push-pins from the wheelhouse liner. 2. Remove the bolt that retains the wheelhouse liner to the rocker molding. 3. Remove the wheelhouse liner from the vehicle. Installation Procedure 1. Install the wheelhouse liner to the vehicle. 2. Install the push-pins that retain the wheelhouse liner to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the wheelhouse liner to the rocker molding. Tighten the bolt to 10 N.m (89 lb in). Page 9648 Page 12451 1. Position the bracket assembly on the seat cushion. 2. Install the 2 bolts securing the bracket assembly to the seat cushion. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat cushion bracket bolts to 25 N.m (18 lb ft). 3. Install the rear seat cushion assembly in the vehicle. Seat Cushion Bracket Replacement - Rear No. 1 - 2 SEAT CUSHION BRACKET REPLACEMENT - REAR NO. 1 (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the rear seat bracket trim covers (1). 3. Remove the rear seat cushion bracket mounting nuts (2). 4. Remove the rear seat cushion bracket. INSTALLATION PROCEDURE Page 11855 Mirror Switch, Driver Door Module (DDM) - C5 Page 6311 6. Remove the park brake shoe. 7. Remove the rear drive axle. 8. Remove the retaining nuts from the backing plate. 9. Remove the backing plate from the rear axle housing. Installation Procedure Page 3917 Abbreviations And Meanings Part 4 Page 8961 Side Air Bag: Diagrams Inflatable Restraint Side Impact Module-Left Page 5699 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Page 9209 Steps 7-12 Page 2781 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 7051 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 11517 4. Install the lower cushion, retainer, and bolt to the radiator support. Tighten the bolts to 80 N.m (59 lb ft). Page 12081 WA9539/47 - WA9539/47 Page 9158 Conversion - English/Metric Part 1 Page 216 Circuit/System Testing Component Testing Page 10453 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6753 OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 713 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) C2 Electronic Brake Control Module (EBCM) C2 Part 1 of 2 Page 5395 Disclaimer Page 106 Theft Deterrent Control Module Connector Views Courtesy Lamp: Connector Views Courtesy/Reading Lamp - LF Page 3106 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 12980 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 6285 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Page 7000 Location View Page 13288 Abbreviations And Meanings Part 26 Page 8327 For vehicles repaired under warranty, use the table. Disclaimer Page 12554 Abbreviations And Meanings Part 22 Page 12486 Page 2558 5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100). 6. Align the installation arbor (1) onto the top of the cylinder bore sleeve (117). 7. Align the pusher block (2) of cylinder bore sleeve installer EN 45680-403 into the groove of fixture EN 45680-401(1). Page 4618 Steps 4-5 Page 1741 Abbreviations And Meanings Part 5 Lighting - Tail Lamp(s) Inoperative Tail Light Bulb: All Technical Service Bulletins Lighting - Tail Lamp(s) Inoperative Bulletin No.: 03-08-42-006B Date: May 26, 2004 INFORMATION Subject: Tail Lamp Circuit Board Now Available For Service Use Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add a part number. Please discard Corporate Bulletin Number 03-08-42-006A (Section 08 - Body and Accessories). A new tail lamp circuit board is now available for service use. If normal diagnosis of a vehicle leads to a failed tail lamp bulb, inspect the bulb socket to ensure proper fit of the bulb into the socket. If the bulb is found to be loose, or if the circuit board has failed, replace both tail lamp circuit boards with the new part number from GMSPO. Technicians are to replace the tail lamp circuit boards, on both sides of the vehicle, using the following procedure: 1. Remove the tail lamp assembly from the vehicle. 2. Remove the tail lamp circuit board from the tail lamp assembly. 3. Inspect for loose tail lamp bulbs in the tail lamp circuit board. Replace the tail lamp bulb and the tail lamp circuit board if necessary. 4. Install the tail lamp circuit board. 5. Install the tail lamp assembly. 6. Replace the tail lamp circuit board on the opposite side of the vehicle using the above procedure. 7. Verify the operation of the tail lamps. Parts Information Page 7499 C500 Part 1 Page 12045 Paint: Application and ID Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Page 12499 Seat Heater: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 6168 Brake Warning Indicator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 2222 Fuse Block - Rear C2 Part 7 Fuse Block - Rear C3 Part 1 Page 8795 1. Connect the HVAC control-auxiliary electrical connector. 2. Install the HVAC control-auxiliary in the console bottom first. 3. Push in at the top of the HVAC control-auxiliary in order to engage the HVAC control-auxiliary in the console/seat. Page 10880 Abbreviations And Meanings Part 16 Page 4354 Powertrain Control Module (PCM) C1 Part 3 Page 4635 the locking tabs. 5. Pull the connection apart. 6. Use a clean shop towel in order to wipe off the male pipe end. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. INSTALLATION PROCEDURE 1. Apply a few drops of clean engine oil to the male pipe end. CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 2. Push both sides of the fitting together in order to snap the retaining tabs into place. ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Two - Person Procedure Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. Caution: Refer to Brake Dust Caution in Cautions and Notices. Important: ^ Use the two-person bleed procedure under the following conditions. Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake Pressure Modulator Valve (BPMV). - Air is trapped in the valve body. ^ Do not drive the vehicle until the brake pedal feels firm. ^ Do not reuse brake fluid that is used during bleeding. ^ Use the vacuum, the pressure and the gravity bleeding procedures only for base brake bleeding. 1. Raise the vehicle in order to access the system bleed screws. . Bleed the system at the right rear wheel first. 3. Install a clear hose on the bleed screw. 4. Immerse the opposite end of the hose into a container partially tilled with clean DOT 3 brake fluid. 5. Open the bleed screw 1/2 to 1 full turn. 6. Slowly depress the brake pedal. While the pedal is depressed to its full extent, tighten the bleed screw. 7. Release the brake pedal and wait 10-15 seconds for the master cylinder pistons to return to the home position. 8. Repeat the previous steps for the remaining wheels. The brake fluid which is present at each bleed screw should be clean and free of air. 9. This procedure may use more than a pint of fluid per wheel. Check the master cylinder fluid level every four to six strokes of the brake pedal in order to avoid running the system dry. 10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure. Release the brake pedal between each test. 11. Bleed all four wheels again using Steps 3-9. This will remove the remaining air from the brake system. 12. Evaluate the feel of the brake pedal before attempting to drive the vehicle. 13. Bleed the system as many times as necessary in order to obtain the appropriate feel of the pedal. Page 13072 Door Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the rear door ajar switches in the door lock assemblies as one method to activate the alarm. The body control module (BCM) monitors rear door ajar switches via a discrete input from each rear passenger door ajar switch, if the BCM receives a ground signal from a rear passenger door ajar switch when the CTD system is armed, the BCM activates the alarm. The CTD system uses the LH front door ajar switch as one method to activate the alarm. The driver door module (DDM) monitors the LH door ajar switch via a discreet input from the door ajar switch, if the DDM receives a ground signal from the LH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the RH front door ajar switch as one method to activate the alarm. The passenger door module (PDM) monitors the RH door ajar switch via a discreet input from the door ajar switch, if the PDM receives a ground signal from the RH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the rear compartment liftgate/liftglass ajar switchs as one method to activate the alarm. The liftgate module (LGM) monitors the liftgate and liftglass ajar switch via a discreet input from the ajar switch, if the LGM receives a ground signal from the liftgate or liftglass ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. Page 2277 Application Table Part 3 Locations Memory/Heated Seat Switches Page 8287 Ambient Temperature Sensor / Switch HVAC: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2 wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and low reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0-5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the following conditions: The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 10488 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 4103 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 1298 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Specifications Idle Speed: Specifications Engine Speed ...................................................................................................................................... .......................................................... 500 - 700 RPM Desired Idle Speed .............................................................................................................................. ........................................................ PCM Controlled Page 3634 Fuel Tank Pressure (FTP) Sensor Page 8719 For vehicles repaired under warranty, use the table. Disclaimer Page 8218 Recirculation Actuator Page 11341 Liftgate Module (LGM) C3 (Except XUV) Page 1173 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front passenger side seat. 2. Remove the park brake warning lamp switch electrical connector. 3. Remove the park brake warning lamp switch retaining screw. 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch retaining screw. ^ Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). 3. Connect the electrical connector. 4. Install the front passenger side seat. Page 3705 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE 1. Install the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Page 6862 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 7294 Registered And Non-Registered Trademarks Part 4 Page 4124 Abbreviations And Meanings Part 10 Page 4300 Body Control Module: Connector Views Body Control Module (BCM) C1 Part 1 Page 7842 3. Remove the outer tie rod retaining nut. 4. Disconnect the outer tie rod from the steering knuckle using J24319-B. 5. Remove the stabilizer shaft link lower retaining nut. 6. Disconnect the stabilizer shaft link and washer from the lower control arm. Page 10874 Abbreviations And Meanings Part 10 Steering - Moan/Groan Shudder on Low Speed Turns Steering Gear: All Technical Service Bulletins Steering - Moan/Groan Shudder on Low Speed Turns Bulletin No.: 04-02-32-007A Date: December 01, 2004 TECHNICAL Subject: Steering System Moan, Groan, Shudder and/or Vibration Type Noise During Low Speed Turning Maneuvers (Replace Steering Gear) Models: 2004-2005 Buick Rainier 2003-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2003-2004 Oldsmobile Bravada Short Wheelbase Utilities Built Prior to VIN Breakpoint 52123375 Long Wheelbase Utilities Built Prior to VIN Breakpoint 56137280 Supercede: This bulletin is being revised to remove the 2002 model year and add the long wheelbase utilities. Please discard Corporate Bulletin Number 04-02-32-007 (Section 02 - Steering). Condition Some customers may comment on a moan, groan, shudder and/or vibration noise while making low speed turning maneuvers. Customers usually notice this condition in parking lot turning maneuvers. Correction 1. Diagnose the power steering concern. Refer to Symptoms - Power Steering System. 2. Replace the steering gear with a newly designed steering gear. See the parts information below. Refer to Power Steering Gear Replacement. Parts Information Parts are currently available from GMSPO. Warranty Information Page 1310 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the windshield garnish moldings. 2. Remove the trim pad. 3. Disconnect the electrical connector from the sensor. IMPORTANT: Cover the windshield defrost vents with clean shop rags. 4. In order to remove the sensor from the trim pad, rotate the sensor counter-clockwise 1/4 turn. 5. Remove the sensor from the trim pad. INSTALLATION PROCEDURE Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 10487 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Wheels/Tires - Use of Nitrogen Gas in Tires Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Page 2767 Page 5105 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 7089 Multiple Junction Connector: Diagrams C201 - C203 C201 Part 1 Page 8647 Hose/Line HVAC: Service and Repair Evaporator Drain Hose EVAPORATOR DRAIN HOSE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the HVAC module-auxiliary. 2. Remove the HVAC module pass through seal (3) from the HVAC module-auxiliary (1). 3. Remove the evaporator drain hose-auxiliary (2) from the HVAC module-auxiliary (1). INSTALLATION PROCEDURE 1. Install the evaporator drain hose-auxiliary (2) to the HVAC module-auxiliary (1). 2. Install the HVAC module pass through seal (3) to the HVAC module-auxiliary (1). 3. Install the HVAC module-auxiliary. Page 8309 40.5. Route the other end of the harness along the rear of the engine compartment to the left side and secure to the cross bar and dash panel with tie straps. Page 10710 Global Positioning System Module: Service and Repair Communication Interface Module Replacement 2 COMMUNICATION INTERFACE MODULE REPLACEMENT (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE 1. Fold and tumble the right second row seat to a cargo position. IMPORTANT: Do not exchange the vehicle communication interface module with other vehicles. Each vehicle communication interface module has a specific station identification (STID) and electronic serial number (ESN). These identification numbers are stored in the General Motors vehicle history files by VIN and used by OnStar(R) and the National Cellular Telephone Network. 2. Remove the protective cover (1) from the vehicle communication interface module (VCIM). 3. Remove the VCIM from the bracket by releasing the retaining tab (1). 4. Remove the electrical connectors from the VCIM. 5. Remove the VCIM from the vehicle. INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. 2. Position the VCIM near the mounting location. Page 8616 Coolant Bypass Valve (Body Type VIN 6) (w/Automatic - HVAC System) Page 8557 6. The O-ring seal must be fully seated. 7. Assemble the A/C components.Refer to the appropriate repair procedure. - For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. - For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Page 13294 Registered And Non-Registered Trademarks Part 6 Page 9653 Page 8646 13. Connect the compressor hose assembly hose to the compressor (4). 14. Install the compressor hose assembly washers. 15. Install the retaining nut (3). Tighten Tighten the nut to .....33 N.m (24 lb ft). 16. Evacuate and recharge the A/C system. 17. Leak test the fittings of the components using the J 39400. Service and Repair Refrigerant Temperature Sensor: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the A/C low pressure switch electrical connector. 2. Remove the A/C low pressure switch (2) from the accumulator (1). 3. Remove and discard the O-ring seal from the A/C low pressure switch port on the accumulator. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the A/C low pressure switch (2) to the accumulator (1). Tighten the A/C low pressure switch to 4.8 N.m (42 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the A/C low pressure switch electrical connector. 4. Leak test the fittings of the components using the J 39400-A. Page 11038 9. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge. INSTALLATION PROCEDURE 1. Position the service hinge (1) within the scribe marks (2) on the door (3). 2. Mark each hole location on the door according to the service hinge (4). 3. Drill a 3 mm (1/8 in.) pilot hole at each marked location (1). 4. Drill a 13 mm (1/2 in.) hole at each pilot hole location (2). 5. Clean and prepare all bare-metal surfaces. IMPORTANT: Prior to refinishing, refer to the publication GM4901MD-2001 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an anti-corrosion primer. 7. Align the hinge (1) and the backing plate (2) with the holes in the door (3). 8. Hand tighten all four supplied bolts (4). 9. Align hinge. Page 12877 Page 145 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 6374 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation. Parts should be ordered on a CSO Customer Special Order. RECALL IDENTIFICATION LABEL - For US and IPC Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials. Request Item Number S-1015 when ordering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. RECALL IDENTIFICATION LABEL - For CANADA Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Ask for Item Number GMP 91 when ordering. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Page 1761 Abbreviations And Meanings Part 25 Page 7568 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 10554 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 9253 Disclaimer Page 5590 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 78 Abbreviations And Meanings Part 23 Page 11669 Headliner: Service and Repair Headliner Replacement - Trailblazer, Envoy, Bravada Headliner Replacement (Trailblazer, Envoy, Bravada) Removal Procedure 1. Ensure the ignition switch is in the LOCK position. 2. Remove the cargo net, if equipped. 3. Remove the luggage/cargo shelf assembly, if equipped. 4. Remove the right sound insulator panel. 5. Remove the front door sill plates. 6. Remove the rear door sill plates. Notice: Remove the headliner and the headliner harness as an assembly. Do NOT cut or splice the headliner harness. Cutting or splicing the harness may damage the coax cable, resulting in poor radio performance. 7. Remove the center pillar trim panels. 8. Remove the windshield garnish moldings. 9. Remove the instrument panel (IP) trim pad. 10. Open the IP compartment door and lower the door to the full down position. 11. Disconnect the coax cable (2) and the headliner harness electrical connector (1), located near the bottom of the HVAC blower motor. 12. Remove the lower rosebud (2) that fastens the headliner harness to the cowl. 13. Remove the 3 clips (1) retaining the headliner harness to the right windshield pillar. 14. Attach a mechanic's wire to the end of the headliner harness. 15. The wire harness is located in the cowl insulation access hole, behind the IP. In order to remove the wire harness, grasp the headliner harness near the bottom of the windshield and carefully pull upward. 16. Leaving the mechanic's wire positioned behind the IP, remove the headliner harness from the mechanics wire. 17. Remove the video display. 18. If equipped, remove the front and rear overhead console. Refer to Overhead Console Replacement - Front, or to Overhead Console Replacement Rear. 19. Remove the sunshades from the headliner. 20. If equipped with OnStar(R), perform the following procedure: 1. Disconnect the navigation antenna cable from the communication interface module. 2. Remove the navigation antenna cable from the right side door rocker panel attachments. 3. Remove the navigation antenna cable from the right center pillar. Page 13024 Abbreviations And Meanings Part 25 Page 2944 Abbreviations And Meanings Part 16 Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Drain and Refill ..................................................................................................... ............................................................................................ 4.7L (5.0 Qt) Page 10061 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 596 Abbreviations And Meanings Part 8 Page 5734 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Page 4230 Page 8234 REMOVAL PROCEDURE 1. Remove the I/P carrier. 2. Remove the air temperature actuator-right retaining screws. 3. Disconnect the air temperature actuator-right electrical connector. 4. Remove the air temperature actuator-right. INSTALLATION PROCEDURE 1. Install the air temperature actuator-right. 2. Tighten the air temperature actuator-right retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb ft). 3. Install the air temperature actuator-right electrical connector. 4. Install the I/P carrier. 5. Recalibrate the air temperature actuator on vehicles equipped with automatic climate control (C68), See: Testing and Inspection/Programming and Relearning Defroster Actuator DEFROSTER ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP carrier. Page 12503 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 1874 Disclaimer Page 2268 Fuse Block: Service and Repair Rear Electrical Center or Junction Block Replacement REAR ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a cargo position. 4. Remove the rear electrical center cover. 5. Remove the battery feed terminal nut (2) from the junction block. 6. Remove the body control module (BCM) from the rear electrical center. 7. Fully loosen the 3 bolts (1) that retain the junction block to the electrical connectors. Page 3520 Body Control Module (BCM) C1 Part 2 Oil Viscosity Engine Oil: Description and Operation Oil Viscosity ENGINE OIL VISCOSITY, UNITED STATES AND CANADA NOTICE: Using oils of any viscosity other than those recommended could result in engine damage. When choosing an oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Then, select the recommended oil viscosity. SAE 5W-30 is the only viscosity grade recommended for your vehicle. Use only oils which have the API Starburst symbol and which are also identified as SAE 5W-30. If the temperature range is-18°F( 0°C) or above SAE 10W-30 oil which has the API Starbust symbol is acceptable if SAE 5W 30 oils is not available. Areas where the temperature falls below -29°F (-20°C), either an SAE 5W-30 synthetic oil or and SAE 0W-30 oil is recommended. Both will provide easier cold starting and better protection for the engine at extremely low temperatures. Do not use other viscosity grade oils, such as SAE 10W-40 or SAE 20W-50 under any conditions. SAE 5W-30 is the recommended engine oil viscosity. Engine oil viscosity thickness has an effect on the fuel economy and the cold-weather operation engine starting and oil flow. Lower viscosity engine oils can provide better fuel economy and cold-weather performance. However, higher temperature weather conditions require higher viscosity engine oils for satisfactory lubrication. When the temperature is consistently above -18°C (0°F), 10W-30 may be used. SAE 20W-50 or oils of other viscosity rating or quality designations are NOT recommended for use in any GMC vehicle at any time. ENGINE OIL QUALITY AND VISCOSITY (OTHER THAN THE UNITED STATES AND CANADA) NOTICE: Using oils of any viscosity other than those recommended could result in engine damage. When choosing an oil, consider the range of temperatures the vehicle will be operated in before the next oil change. Then, select the recommended oil viscosity. Page 5502 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Slde Page 4637 Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Plastic Collar) REMOVAL PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. IMPORTANT: There are several types of Plastic Collar Fuel and Evaporative Emission Quick Connect Fittings used on this vehicle. Bartholomew (1) - Q Release (2) - Squeeze to Release (3) - Sliding Retainer (4) The following instructions apply to all of these types of Plastic Collar Quick Connect Fittings except where indicated. 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief Procedure. 2. Using compressed air, blow any dirt out of the quick-connect fitting. CAUTION: Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Service Precautions. - Refer to Safety Glasses Caution in Service Precautions. Page 8902 5. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 6. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Page 12179 Abbreviations And Meanings Part 24 Page 9919 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Service and Repair Memory Positioning Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the 3 seat switch bezel screws. 2. Remove 4 nuts that attach the seat pan to the seat assembly. 3. Remove the clip from the front outboard seat pan stud. Discard the clip. 4. Lift the seat pan up in order to allow access to the seat control module retaining screw. 5. Remove the seat control module retaining screw. 6. Disconnect the electrical connectors from the seat control module as necessary. 7. Remove the seat control module from the seat assembly. INSTALLATION PROCEDURE 1. Align and install the locating tabs on the seat control module with the seat pan. 2. Connect the electrical connectors to the seat control module as necessary. Locations Stop Lamp Switch Page 958 1. Install the PCM mounting studs to the intake manifold, if removed. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the studs to 6 N.m (53 lb in). 2. Install the PCM (2) to the intake manifold. 3. Install the PCM mounting nuts and bolts (4). Tighten Tighten the nuts and bolts to 10 N.m (88 lb in). 4. Install the PCM harness connectors (3) to the PCM body. 5. Tighten the PCM harness connector retaining bolts (1). Tighten Tighten the bolts to 8 N.m (71 lb in). 6. If a new PCM is being installed, the PCM must be programmed. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. See: Testing and Inspection/Programming and Relearning Page 5010 Park/Neutral Position Switch (C2) Page 1041 Page 513 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 2649 Accessory Drive Belt Routing Locations Seat Belt Buckle Page 2819 Abbreviations And Meanings Part 17 Page 9791 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 9096 Impact Sensor: Diagrams Inflatable Restraint Side Impact Sensor (SIS) Inflatable Restraint Side Impact Sensor (SIS) - Left Page 8950 9. Position the headlamp wire harness (1) to the retaining clip. 10. Install and secure the headlamp wire harness in the retaining clip (1). 11. Install the grille. 12. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Page 12470 Seat Cushion Bracket Replacement - Rear No. 1 (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the rear seat cushion assembly from the vehicle.. 2. Remove the 2 bolts securing the bracket assembly to the seat cushion. 3. Remove the bracket assembly from the seat cushion. Installation Procedure 1. Position the bracket assembly on the seat cushion. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 2 bolts securing the bracket assembly to the seat cushion. Tighten the rear seat cushion bracket bolts to 25 N.m (18 lb ft). 3. Install the rear seat cushion assembly in the vehicle. Seat Cushion Bracket Replacement - Rear No. 1 (TrailBlazer EXT, Envoy XL) Seat Cushion Bracket Replacement - Rear No. 1 (Trailblazer EXT, Envoy XL) Page 3452 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 7233 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 1035 and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Liftgate Module (LGM) Power Trunk / Liftgate Control Module: Diagrams Liftgate Module (LGM) Liftgate Module (LGM) C1 (Except XUV) Page 1747 Abbreviations And Meanings Part 11 Page 5146 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 10818 Page 2336 Tires: Diagrams Tire Rotation In order to equalize wear, rotate the tires at the specified intervals. In addition to scheduled rotation, rotate the tire and wheel assembly whenever you notice uneven tire wear. Radial tires tend to wear faster in the shoulder area, particularly in front positions, due to design. Radial tires in non-drive locations may develop an irregular wear pattern that can generate tire noise. This especially makes regular tire rotation necessary. - For vehicles with single rear wheels (four tires), rotate the tires as shown. - For vehicles with single rear wheels (five tires), rotate the tires as shown. - For vehicles with dual rear wheels (same tire sizes and load ranges), rotate the tires as shown. Page 11811 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 8325 40.6. Install the ring terminal (orange wire) to the underhood fuse block stud (1). 40.7. Locate circuit no. 241 or 441 (ignition 3 brown wire) (PIN B11 or C11) in the existing underhood fuse block harness (1) of C2 (2) and splice bare wire to it using a splice clip. Wrap with electrical tape. 40.8. Locate connector C105 (3), located on the left side inner fender. Separate the connector halves. On the female side of the connector, remove the terminal from cavity F (gray/black wire) and tape back. 40.9. Install the terminal end on the pump wiring harness into cavity F of connector C105. 41. Install the evaporator tube and nut to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 42. Install the coolant recovery reservoir with the accumulator attached. 43. Install the nut and bolt securing the coolant recovery reservoir. 44. Install the coolant hoses to the coolant recovery reservoir. 45. Install the nut retaining the accumulator to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 46. Install the compressor suction hose assembly to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). Page 3525 Body Control Module (BCM) C3 Part 4 Page 4943 Spark Plug: Testing and Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 1988 Disclaimer Page 5876 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the ABS sensor mounting bolt from the wheel hub and bearing. 5. Remove the ABS sensor from the wheel hub and bearing. 6. Remove the wheel hub and bearing to the steering knuckle mounting bolts. 7. Remove the wheel hub and bearing from the steering knuckle. 8. Remove the splash shield from the steering knuckle. Page 12982 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Service and Repair Marker Lamp Bulb: Service and Repair PARK/TURN SIGNAL/SIDE MARKER LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Rotate the bulb and socket counterclockwise in order to remove the bulb and socket from the housing. 3. Remove the side marker bulb (4) or turn signal/park bulb (3) from the socket. INSTALLATION PROCEDURE 1. Install the side marker bulb (4) or turn signal/park bulb (3) to the socket. 2. Wipe the bulb with a clean cloth to ensure the bulb is free of any dirt or oil. 3. Install the bulb and socket to the headlamp by rotating the bulb and socket clockwise, locking the retaining tabs to the headlamp. 4. Close the hood. Page 3194 Coolant: Description and Operation Cooling System The cooling system's function is to maintain an efficient engine operating temperature during all engine speeds and operating conditions. The cooling system is designed to remove approximately 1/3 of the heat produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not flow to the radiator until the thermostat opens. This allows the engine to warm quickly. Cooling Cycle Coolant is drawn from the radiator outlet and into the water pump inlet by the water pump. Coolant will then be pumped through the water pump outlet and into the engine block. In the engine block, the coolant circulates through the water jackets surrounding the cylinders, where the coolant absorbs heat. Some coolant is also pumped from the water pump to the heater core, then back to the water pump. This provides the passenger compartment with heat and defrost. The coolant is then forced through the cylinder head gasket openings and into the cylinder heads. In the cylinder heads, the coolant flows through the water jackets surrounding the combustion chambers and valve seats, where the coolant absorbs additional heat. Coolant is also directed to the throttle body. There the coolant circulates through passages in the casting. During initial start up, the coolant assists in warming the throttle body. During normal operating temperatures, the coolant assists in keeping the throttle body cool. From the cylinder heads, the coolant is then forced to the thermostat. The flow of coolant will either be stopped at the thermostat until the engine is warmed, or the coolant will flow through the thermostat and into the radiator where the coolant is cooled and the coolant cycle is completed. Operation of the cooling system requires proper functioning of all cooling system components. The cooling system consists of the following components, which are described below: - The coolant - The radiator - The pressure cap - The coolant recovery system - The air baffles and seals Coolant The engine coolant is a solution made up of a 50-50 mixture of DEX-COOL and suitable drinking water. The coolant solution carries excess heat away from the engine to the radiator, where the heat is dissipated to the atmosphere. Page 9927 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 10846 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 6980 Fuse Block - Underhood C4 Part 2 Page 12804 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 12472 4. Remove the 3 bolts securing the rear seat cushion latch to the seat pan. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the 3 bolts securing the rear seat cushion latch to the seat pan. Tighten the rear seat cushion latch release bolts to 10 N.m (88 lb in). 2. Install the small loop (1) onto the rear seat cushion latch (2). 3. Install the strap through the opening in the seat pan. 4. Install the rear-seat cushion cover and the pad. 5. Install the rear seat cushion assembly to the vehicle. Seat Cushion Cover and Pad Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada) Seat Cushion Cover and Pad Replacement - Rear No. 1 (Trailblazer, Envoy, Bravada) Tools Required J 36796Clip Removal Tool Removal Procedure 1. Remove the seat cushion from the vehicle. 2. Remove the seat cushion bracket. Page 7916 Compressor/Pump: Service and Repair Air Spring Compressor Replacement Removal Procedure Caution: Refer to Sudden Release of Pressure in the Air Suspension System Caution in Service Precautions. Notice: Depressurize the air suspension system only after the rear axle is supported and is set between D - Height and Full Jounce. Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensor to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the air spring compressor to the frame mounting bolts. 4. Disconnect the air inflator switch electrical connection, air supply lines, and air spring compressor vent hose from the air spring compressor. Page 12194 Memory Seat Switch, Driver Door Module (DDM) - C4 Page 5478 Park/Neutral Position Switch (C2) Page 2554 For vehicles repaired under warranty, use the table. Disclaimer Page 5065 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Page 10153 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Page 72 Abbreviations And Meanings Part 17 Page 240 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Recall 05V198000: Flasher Module Replacement Hazard Warning Flasher: All Technical Service Bulletins Recall 05V198000: Flasher Module Replacement MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2004 Chevrolet/Trailblazer 2003-2004 GMC/Envoy 2003-2004 Isuzu/Ascender 2003-2004 Oldsmobile/Bravada 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V198000 RECALL DATE: April 29, 2005 COMPONENT: Exterior Lighting: Turn Signal POTENTIAL NUMBER OF UNITS AFFECTED: 286478 SUMMARY: On certain trucks and sport utility vehicles, the driver wishing to signal a turn by moving the directional signal lever, (up or down) may cause the front marker/turn lights and rear turn lights to flash in a manner similar to hazard warning, rather than flashing on the desired side only. CONSEQUENCE: The driver may not be able to clearly signal their intentions to turn, change travel lanes, or potentially warn others of an impaired vehicle operating condition increasing the risk of a crash. REMEDY: Dealers will replace the suspect flasher modules with a new flasher module designed with sealed relays and more durable contact material inside of the relays. The recall is expected to begin during August 2005. owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727, Buick at 1-866-608-8080, and Oldsmobile at 1-800-630-6537. NOTES: GM recall No. 05044. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Page 6652 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Body - Luggage Carrier Cross Rail Optimum Positioning Roof Rack Frame: Technical Service Bulletins Body - Luggage Carrier Cross Rail Optimum Positioning File In Section: 08 - Body and Accessories Bulletin No.: 04-08-67-006 Date: September, 2004 INFORMATION Subject: Proper Positioning of Luggage Carrier Cross Rails to Avoid Windrush Models: 2004-2005 Buick Rainier 2003-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2003-2004 Oldsmobile Bravada The purpose of this bulletin is to inform technicians of a windrush that may occur when the luggage carrier cross rails are out of position. Experience has shown that some customers may comment on windnoise generated by the presence of luggage carrier (roof rack) cross rails. The disturbance becomes more noticeable as the cross rails are placed in positions over the driver and passenger seating areas. The optimal installation locations of the cross rails to minimize wind disturbance are with the front cross rail positioned in line with the rear edge of the rear door, and the rear cross rail positioned 50.8 mm (2 in) forward of the rear edge of the side rail. Vehicles ordered with production installed will be placed in these locations. Luggage carrier cross rails for a GMC Envoy XUV are a Regular Production Accessory and will be received at your dealership separately for your installation prior to delivery. Please use these same cross rail positions when all luggage carrier cross rails are installed during your pre-delivery inspection (PDI) process. ^ Pull up on the lever on each side of the cross rail. ^ Place the front cross rail in line with the rear edge of the door and push down on the lever to lock it in place. Refer to the illustration above. Page 12810 5. Tape over the entire cable. Use a winding motion when you apply the tape. Body - Front/Rear Side Door Glass is Scratched Window Seal: Customer Interest Body - Front/Rear Side Door Glass is Scratched Front or Rear Side Door Glass Scratched (Adjust Hem Flange) # 04-08-64-012C - (May 26, 2005) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada This bulletin is being revised to correct the model designations for the last four parts listed in the Parts Information table. Please discard Corporate Bulletin Number 04-08-64-012B (Section 08 -Body and Accessories). Condition Some customers may comment that the front or rear door glass has some vertical scratches on the outside of the door glass. Cause The inner and outer belt moldings may be too tight, causing dirt to get impregnated into the outer belt molding and causing scratches. Correction 1. Remove the Door Trim Panel-Side Front Door. Remove the outer belt molding. 2. Take a measurement between the inner and outer hem flange at the top of the door. Refer to the illustration above. If that measurement is 27 mm (1.06 in) or lower, proceed to step 3. 3. Close the door. 4. Wearing gloves, pull on the outer door skin to achieve a measurement of 28 mm (1.10 in) minimum to 31 mm (1.22 in) maximum. If the measurement cannot be achieved by pulling, use a pair of Vise Grip (Sheet Metal) pliers and bend the outer panel to get your measurement. 5. Install a new reveal molding. 6. Install a new door glass. Page 9379 Abbreviations And Meanings Part 13 Page 6776 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 1234 3. Disconnect the electrical connector (3) from the air temperature sensor-lower right (2). 4. Remove the air temperature sensor-lower right (2). INSTALLATION PROCEDURE 1. Install the air temperature sensor-lower right (2). 2. Connect the electrical connector (3) to the air temperature sensor-lower right (2). 3. Install the IP lower closeout panel. 4. Install the passenger side closeout panel. Upper Left AIR TEMPERATURE SENSOR REPLACEMENT - UPPER LEFT REMOVAL PROCEDURE 1. Remove the radio. 2. Remove the HVAC control module. Page 12231 Memory Seat Module - Driver C4 Part 3 Page 6770 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 9338 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 12159 Abbreviations And Meanings Part 4 Page 12851 Registered And Non-Registered Trademarks Part 2 Page 6351 2. Install the piston seal. Make sure the piston seal is not twisted in the caliper bore groove. 3. Install the boot into the caliper housing bore by hand. 4. Install the piston in the caliper bore. Push the piston to the bottom of the bore by hand. 5. Install the boot on the piston. Page 6434 ^ If the brake pipe does NOT have the tooling mark (2), proceed to the next step of the inspection. 6. Clean and remove any dirt from the left front brake pipe and flare nut (3) where it connects to the ABS modulator under the vehicle. The left front pipe is on the top row and closest to the center of the vehicle. 7. Carefully inspect the brake pipe where the pipe goes into the flare nut for the same type of tooling mark (1) as shown above. The mark may be located at any point around the circumference of the pipe and a mirror flashlight may be required to see it. There will NOT be any of the spiral lines or grooves (2) in the tooling mark. ^ If the tooling mark IS present, then the brake pipe does NOT need to be replaced. Lower the vehicle and install the GM Recall Identification Label. ^ If the tooling mark is NOT present, then the brake pipe must be replaced. Proceed to the Replacement procedure, below. Replacement Procedure This replacement procedure should only be performed if the results of the Inspection procedure indicated that the brake pipe needed to be replaced. Bleeding of the hydraulic system is done using a pressure bleeder and is limited to the left front brake. This pressure bleeding procedure is a shortened version of the full vehicle procedure found in the Service Manual. As a result, the labor time included in this recall for bleeding the brake system is less. Important To avoid unnecessary brake fluid loss, have the new brake pipe ready to install before you begin removing the old pipe. 1. Disconnect the brake pipe (1) from the left front caliper brake hose fitting. 2. From underneath the vehicle, disconnect the other end of the brake pipe (1) from the ABS modulator located on the inboard side of the left frame rail. 3. Disconnect the pipe from the lower retainers on the frame. 4. Disconnect the pipe from the upper retainer on the frame. Page 9424 Page 11121 11. Remove the feed wire (1) from the hinge. Notice: Refer to Fastener Notice in Service Precautions. Tighten the 4 bolts. 13. Align the hinge to the original scribe location. Torque all of the 4 bolts to 25 N.m (18 ft lb). Install and hand tighten the 2 remaining bolts. 14. Clean and prepare all bare-metal surfaces. 15. Apply a full-bodied caulk around the service hinge (1). 16. Refinish as necessary. 17. Install and align all of the related panels and components. Page 135 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 1624 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 7108 C309 (Long Wheelbase, Body Type VIN 6) Part 1 Rear Window Defogger Grid Rear Window Defogger Grid Page 6961 Fuse Block - Rear C3 Part 3 Page 9257 IMPORTANT: - The adhesion promoter must be used to assure adequate bonding of the coupling. - Mask or protect the surrounding area before applying the adhesion promoter. Remove the protective film from the adhesive backing on the inner antenna coupling. IMPORTANT: Ensure the inner and outer antenna couplings are aligned. - Do not touch the adhesive backing on the antenna coupling. 1. If the exterior antenna coupling is not installed, use a grease pencil on the outside glass to mark the mounting location of the interior antenna coupling. Ensure the marks are level. 2. The mounting location for the couplings is on the left quarter window, 100 mm (4 in) (A) rearward of the black masking (1), and 48 mm (2 in) (B) below the black masking. 3. If the exterior antenna coupling is installed, align the inner antenna coupling to the exterior coupling. 4. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the back glass (4). Hold pressure on the inner coupling (2) for 10-30 seconds. 5. Inspect the installation to ensure that no surface gaps are present between the couplings (5,2) and the back glass (4). Page 2430 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the ABS sensor mounting bolt from the wheel hub and bearing. 5. Remove the ABS sensor from the wheel hub and bearing. 6. Remove the wheel hub and bearing to the steering knuckle mounting bolts. 7. Remove the wheel hub and bearing from the steering knuckle. 8. Remove the splash shield from the steering knuckle. Page 2613 Bolt Extractor Tool Kit Part Number EN-47702 The bolt extractor kit EN-47702 provides the following components to assist in removal of the broken bolt segment: 1. One 5/32" reverse twist drill - part number EN-47702-6 2. One double-ended drill pilot insert - part number EN-47702-1 (ensures a straight drilling procedure) 3. Drill pilot inserts for larger diameter heads or main cap bolts - part number EN-47702-2 (ensure a straight drilling procedure) 4. Bolt extraction # 3 EZ out - part number EN-47702-3 (after the drilling procedure) 5. Bottom tap (M11 X 2) - part number EN-47702-5 (for the head bolts to chase the threads after the completion of bolt removal) 6. Bottom tap (M10 X 1.5) - part number EN-47702-4 (for the main bolts to chase the threads after the completion of bolt removal) Disclaimer Page 7024 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 10663 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 7735 10. Install the lower intermediate shaft retaining bolt to the power steering gear. Tighten the lower intermediate shaft pinch bolt to the power steering gear to 40 Nm (30 ft. lbs.). 11. Connect the outer tie rods to the steering knuckles. 12. Install the outer tie rods to steering knuckles retaining nuts. Tighten the outer tie rods to steering knuckles retaining nuts to 45 Nm (33 ft. lbs.). 13. Install the tires and wheels. 14. Remove the drain pan from under the vehicle. 15. Lower the vehicle. 16. Bleed the power steering system. 17. Adjust the front toe. Page 31 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 6660 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 796 8. Release the tabs that retain the junction block to the block base. 9. Remove the junction block from the block base. 10. Disconnect the instrument panel harness connector (1) from the junction block. 11. Disconnect the mobile telephone harness connector (1) from the junction block. Page 7871 Ride Height Sensor: Service and Repair Air Spring Leveling Sensor Replacement Removal Procedure Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensor to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Ensure that the vehicle is parked on level surface. 3. Inspect tires for proper tire pressure. 4. Inspect the air suspension system components for damage or defects. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the rear tire and wheels. 7. Support the rear axle and set the rear axle to proper D height. 8. Disconnect the air spring level sensor link from the upper control arm. 9. Disconnect the air spring level sensor electrical connector. Page 12259 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement (TrailBlazer, Envoy, Bravada)Headliner Replacement (TrailBlazer EXT, Envoy XL) in Interior Trim. 2. Disconnect the inline connector from the sunroof electrical harness. 3. With an assistant, remove the sunroof module assembly from the vehicle and place on a clean, prepared surface. 4. Remove the sunroof motor/actuator. 5. Remove the screw that retains the sunroof control module to the mounting bracket. 6. Disconnect the 2 electrical connectors from the sunroof control module. 7. Remove the sunroof control module from the mounting bracket. INSTALLATION PROCEDURE 1. Position the sunroof control module to the mounting bracket. IMPORTANT: Ensure that the drive gear is fully indexed and seated to the drive cables. 2. Install the screw that retains the sunroof control module to the mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the sunroof control module screw to 3 N.m (27 lb in). 3. Connect the 2 electrical connectors to the sunroof control module. 4. Install the sunroof motor/actuator to the sunroof module assembly. 5. With an assistant, install the sunroof module assembly to the vehicle. 6. Connect the inline connector on the sunroof electrical harness. 7. Install the headliner. Page 585 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 10243 Navigation System: Service and Repair Navigation Control Processor Bracket Replacement 2 NAVIGATION CONTROL PROCESSOR BRACKET REPLACEMENT (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE 1. Fold and tumble the right rear seat to a cargo position. 2. Leaving the electrical connectors attached, remove the communication interface module from the vehicle communication interface module (VCIM) bracket. 3. Using a flat bladed tool, release the retaining tab (1) on the VCIM bracket. 4. Slide the VCIM bracket rearward until the retaining tabs are released from the seat bracket. 5. Remove the VCIM bracket from vehicle. 6. Slide the VCIM bracket rearward until the retaining tabs are released from the seat bracket. 7. Remove the VCIM bracket from vehicle. INSTALLATION PROCEDURE Page 212 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 13252 Various symbols in order to describe different service operations. Page 12854 Registered And Non-Registered Trademarks Part 5 Page 2090 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Grade ................................................................................................................................................... .................................................................... Synthetic Viscosity .......................................................... ......................................................................................................................................................... 75W-90 Page 7202 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 8080 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 10916 3. Connect the 24-way gray electrical connector (1) to the BCM. 4. Connect the 32-way tan electrical connector (2) to the BCM. 5. Connect the 40-way body wiring extension (1) to the BCM. 6. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. Page 7099 C304 Part 2 Page 12464 Seat Cushion: Removal and Replacement Seat Cushion Frame Replacement - Front Seat Cushion Frame Replacement - Front Removal Procedure 1. Remove the 3 seat switch bezel mounting screws. 2. Remove the 4 nuts that secure the seat pan to the power seat adjuster frame. 3. Remove the clip from the front outboard seat pan stud, if equipped. Discard the clip. 4. Disconnect the black electrical connector (6) from the seat back harness. 5. Disconnect the black electrical connector (3) from the seat belt buckle. 6. Disconnect the gray lumbar electrical connector (5), if equipped. 7. Remove the SIR harness (2) from the harness clips (1, 4), and remove the SIR harness from the seat. 8. Remove the seat harness from the seat pan. 9. Remove the seat memory module, if equipped. 10. Remove the seat cushion assembly. 11. Remove the seat cushion cover and pad from the seat frame. 12. Remove the wiring harness and connector clips, if you are replacing the frame. Installation Procedure 1. Install the wiring harness and connector clips, if you replaced the frame. 2. Install the seat memory module, if equipped. 3. Install the seat cushion cover and pad to the seat frame Page 2962 Oil Pressure Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Fuse Block - Rear (Long Wheelbase) Fuse Block: Application and ID Fuse Block - Rear (Long Wheelbase) Location View Page 337 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 7781 8. Remove the upper intermediate shaft to steering column pinch bolt. 9. Disconnect the upper intermediate shaft from the steering column. 10. Remove the upper intermediate shaft from the vehicle. Installation Procedure 1. Install the upper intermediate shaft to the vehicle. 2. Connect the upper intermediate shaft to the steering column. Notice: Refer to Fastener Notice in Service Precautions. Important: The upper intermediate shaft to the steering column pinch bolt must be installed in the same direction it was removed or the pinch bolt will contact the steering column housing. 3. Install the upper intermediate shaft to the steering column pinch bolt and nut. Tighten the upper intermediate shaft to the steering column pinch bolt nut to 50 Nm (37 ft. lbs.). Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 11633 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the LF door trim panel. 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. Page 7888 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 322 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: Customer Interest Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 1533 Knock Sensor (KS) 2 Front Page 74 Abbreviations And Meanings Part 19 Page 8801 Air Temperature Sensor-Lower Right Ignition Coil 1 Ignition Coil 1 Page 1334 Miniwedge (Door Jamb Switch) - LR Service and Repair Front Door Window Motor: Service and Repair Window Regulator Motor Replacement - Door Removal Procedure 1. Remove the window regulator. 2. Remove the bolts retaining the window regulator motor to the window regulator. 3. Remove the window regulator motor from the window regulator. Installation Procedure 1. Install the window regulator motor to the window regulator. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the window regulator motor to the window regulator. Tighten the window regulator motor retaining bolts to 5 N.m (9 lb in). 3. Install the window regulator. Page 6557 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the electrical connectors from the EBCM (2). 2. Remove the four T 25-TORXmounting screws (1) that fasten the EBCM (2) to the BPMV (3). 3. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not use a tool to pry the EBCM or the BPMV. 4. Clean the BPMV (3) to EBCM (2) mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) on to the BPMV (3). Page 9214 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS DATA Battery Voltage: The scan tool displays the battery system voltage. INPUT Left Rear Door Jamb Switch: The scan tool displays the position of the left rear door. The scan tool displays On when the door is open. Right Rear Door Jamb Switch: The scan tool displays the position of the right rear door. The scan tool displays On when the door is open. Ignition 0: The scan tool displays the position of the ignition switch. The scan tool displays On when the ignition switch is in the Accessory, RUN or CRANK position. Ignition 1: The scan tool displays the position of the ignition switch. The scan tool displays On when the ignition switch is in the Run or Crank position. Ignition 3: The scan tool displays the position of the ignition switch. The scan tool displays On when the ignition switch is in the RUN position only. Ignition Accessory: The scan tool displays the position of the ignition switch. The scan tool displays On when the ignition switch is in the Accessory or RUN position only. Scan Tool Data List Scan Tool Output Controls Page 9323 Page 13267 Abbreviations And Meanings Part 5 Page 2108 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Remove the oil fill cap. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the oil pan drain plug and drain the oil into a suitable container. Important: 0mCheck the old oil filter to ensure the filter seal is not left on the engine block. 4. Remove the oil filter using a suitable wrench. 5. Wipe the excess oil from the oil filter housing. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. NOTICE: Refer to Fastener Notice in Service Precautions. See: Engine, Cooling and Exhaust/Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the new oil filter. Tighten the oil filter to 17 Nm (22 ft. lbs.) plus 150°. 3. Install the oil pan drain plug. Tighten the oil pan drain plug to 26 Nm (19 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. Page 9372 Abbreviations And Meanings Part 6 Instruments - Erratic Speedometer Operation Engine Control Module: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 1292 Miniwedge (Door Jamb Switch) - LR Page 12992 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 4366 Powertrain Control Module (PCM) C3 Part 4 Page 11432 Trunk / Liftgate Striker: Service and Repair Lock Striker Replacement - Lift Gate Removal Procedure 1. Open the liftgate. 2. Using a grease pencil, mark the position of the liftgate striker to the body. 3. Remove the bolts that retain the liftgate striker to the body. 4. Remove the striker from the body. Installation Procedure 1. Install the striker to the body and position as previously marked. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the striker to the body. Tighten the bolts to 25 N.m (18 lb ft). 3. Adjust the striker, if necessary. 4. Close the liftgate. Page 9085 2. Install the seat belt bracket (1) to the seat back frame with the 2 bolts (2). Tighten Tighten the rear seat belt bracket mounting bolts to 35 N.m (26 lb ft). 3. Install the seat back cover and pad to the seat back. 4. Install the seat belt (1) to the seat frame with the rear seat belt anchor nut (2). Tighten Tighten all rear center seat belt anchor nut to 60 N.m (44 lb ft). 5. Install the inboard rear seat back cushion hinge cover with 3 screws. Page 6326 Brake Bleeding: Service and Repair Manual Bleeding Procedure Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7- 11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Page 13057 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 4. Install the RF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 3. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. Page 1541 Page 8403 Abbreviations And Meanings Part 23 Engine/Transmission - Flexplate/Flywheel Replacement Flex Plate: Technical Service Bulletins Engine/Transmission - Flexplate/Flywheel Replacement File In Section: 06 - Engine/Propulsion System Bulletin No.: 03-06-01-003 Date: February, 2003 INFORMATION Subject: Flywheel/Flexplate Replacement Models: 2003 Passenger Cars and Light Trucks When replacing the starter for any reason, the flywheel/flexplate should be inspected before replacement. The flywheel/flexplate should be turned a full 360 degrees and inspected for missing or broken teeth or signs of starter milling on the sides of the teeth before replacement. No flywheel/flexplate should be replaced without a visual defect. The majority of flywheel/flexplates returned to GM after replacement under warranty show no signs of damage or defect. Disclaimer Page 13528 4. Position the lens to the headliner with the horizontal tab facing forward. 5. Position the horizontal tab above the headliner and push the lens forward to seat the tab. 6. Push upward on the rear portion of the lens, in order to seat the rear lens retaining tab. 7. Pull down on the lens to ensure that the lens is secured to the headliner. Fuel Injector #1 Fuel Injector 1 Page 2782 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 13293 Registered And Non-Registered Trademarks Part 5 Body - Rear License Plate Pocket Gasket is Loose License Plate Bracket: Customer Interest Body - Rear License Plate Pocket Gasket is Loose Bulletin No.: 04-08-66-001E Date: December 13, 2007 TECHNICAL Subject: Rear License Plate Pocket Perimeter Gasket Loose/Out of Position Or Excessive Amount Of Adhesive (Install New Gasket Using Updated Retainer Tightening Sequence) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2008 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and change the part numbers. Please discard Corporate Bulletin Number 04-08-66-001D (Section 08 - Body & Accessories). Condition Some customers may comment that the insulating perimeter seal or gasket on the backside edge of the license plate housing/pocket appears to be shrinking or becomes pulled away from the edge of the license plate housing/pocket. Some customers may also comment about excessive amounts of adhesive oozing from the gasket. Cause This condition may be caused by changes in temperature, which may cause the plastic license plate housing to expand and contract. When this occurs, the license plate housing gasket seal may be caught and pulled under the housing/pocket. Correction A new gasket without the adhesive has been released for service. Technicians are to replace the rear license plate pocket perimeter gasket using the following procedure: Excessive amounts of adhesive, which may have oozed from the gasket, may be cleaned using GM Tar and Road Oil Remover, P/N 1050172 (in Canada, P/N 992856), or the equivalent. Remove the rear license plate pocket assembly. Refer to the License Plate Pocket Replacement procedure in the Body Rear End (2006 MY and prior) or Exterior Trim sub-section of SI. Remove the rear license plate pocket perimeter gasket. Page 7102 C305 Part 3 Page 9438 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Locations Page 8657 4. Connect the heater hoses to the heater core. 5. Connect the evaporator tube (4) to the evaporator (1). 6. Install the accumulator (6) to the evaporator (1). 7. Tighten the accumulator retaining nut. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the nut to 4.5 N.m (40 lb in). 8. Install the I/P carrier. 9. Evacuate and recharge the A/C system. 10. Leak test the fittings of the components using the J 39400. 11. Refill the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6) Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. Page 2044 Tighten the power steering pressure hose to the power steering pump to 25 Nm (18 ft. lbs.). 4. Install the power steering hose assembly to front crossmember bracket mounting bolt. Tighten the power steering hose assembly to front crossmember bracket mounting bolt to 10 Nm (89 inch lbs.). 5. Install the power steering hose assembly to frame brackets retaining bolts. Tighten the power steering hose assembly to frame brackets retaining bolts to 10 Nm (89 inch lbs.). 6. Connect the power steering hose assembly bracket to the wheel well. 7. Install the power steering hose assembly bracket retaining bolt at the wheel well. Tighten the power steering hose assembly bracket retaining bolt at the wheel well to 10 Nm (89 inch lbs.). 8. Install the fuse block. 9. Install the battery tray. 10. Connect the fuse block harnesses to the wiring loops. 11. Raise the vehicle. 12. Install the power steering return hose and the power steering cooler hose to the power steering cooler. 13. Remove the power steering gear oil seals from the power steering gear using J44586. Notice: Clean the power steering gear inlet and outlet ports thoroughly of any debris. Failure to do so could result in contamination and damage to the power steering system components. 14. Clean the power steering gear inlet and outlet ports of any debris. 15. Install the power steering gear oil seals to the power steering gear using J44586. Page 9528 Page 7738 Important: Do not cut the end of the boot or place a screwdriver between boot and tie rod. Damage to the gear assembly may result. 5. Firmly pull rack and pinion boot (1) from the gear. Discard the rack and pinion boot (1). Installation Procedure Important: The arrows (2) on the boot must be aligned with the range (1) on the gear housing. Page 1140 Heated Seat Element And Thermistor Assembly - Front Passenger Back Page 1518 16. Remove the nut and bolt securing the coolant recovery reservoir. 17. Remove the coolant recovery reservoir with the accumulator attached. 18. Remove the evaporator tube nut at the evaporator. 19. Remove the evaporator tube from the evaporator 20. Using the J 43181, disconnect the heater hoses from the core. 20.1. Install the J 43181 to the heater core hose. 20.2. Close the tool around the heater core hose. 20.3. Firmly pull the tool into the quick connect end of the heater hose. 20.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 21. Disconnect the coolant bypass valve hose from the auxiliary rear heater line. 22. Disconnect the coolant bypass valve hose from the engine. 23. Disconnect the electrical connector from the coolant bypass valve. This connector will no longer be used. Tape off with electrical tape. 24. Disconnect the vacuum hose from the coolant bypass valve. 25. Remove the nut retaining the coolant bypass valve to the cowl and remove the coolant bypass valve with hoses attached. 26. Remove the heater hose quick connect retainers from the heater core pipes. 27. Remove the four nuts and the HVAC plate from the dash panel. 28. Attach the new auxiliary heater pump to the new bracket using the supplied retainers as shown. Note the position of the pump on the bracket. Page 204 Page 13499 Center Mounted Brake Lamp: Service and Repair HIGH MOUNTED STOP LAMP REPLACEMENT (ENVOY, TRAILBLAZER, RAINIER, BRAVADA) REMOVAL PROCEDURE 1. Open the liftgate. 2. Lower the rear portion of the headliner by releasing the 2 headliner retaining pins. 3. Disconnect the high mount stoplamp electrical connector (2). 4. Remove the grommet (1) from the body 5. Close the liftgate. NOTE: Do NOT raise the liftgate while the liftgate glass is open. This can result in damage to the high-mounted stoplamp, the liftgate hinges, or the liftgate glass. 6. Open the liftgate window. 7. Remove the 2 screws that retain the high mount stoplamp to the lift gate window reveal molding. 8. Remove the high mount stoplamp from the vehicle. INSTALLATION PROCEDURE Page 4543 Accelerator Pedal Position (APP) Sensor Page 932 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Specifications Oil Pressure Sensor: Specifications Oil Pressure Sensor 15 ft. lbs. Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 9690 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 11771 Cooling System - Electro-Viscous Fan Clutch Operation Fan Clutch: All Technical Service Bulletins Cooling System - Electro-Viscous Fan Clutch Operation Bulletin No.: 06-06-02-003 Date: February 14, 2006 INFORMATION Subject: Operating Characteristics of the Electro-Viscous (EV) Fan Clutch and Diagnostic Tips for Cooling Fan Noise, Delayed Transmission Shifts and/or Engine Revving Too High Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer SS 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X with 4.2L I-6, 5.3L V-8 or 6.0L V-8 Engine (VINs S, P, M, H - RPOs LL8, LM4, LH6, LS2) Date/VIN Breakpoints for Vehicles with New EV Fan Clutch Vehicles built after and including the Date or VIN Breakpoints listed in the table shown are equipped with the new electro-viscous (EV) fan clutch. Vehicles of any model year listed in "Models Affected" with labor code J3390 (claimed after June 8, 2005) with P/N 15293048 in Claim History may also be equipped with this new EV fan clutch. After having service for poor HVAC performance and/or engine cooling performance, some vehicles may exhibit fan noise, delayed transmission shifts, or the engine revving too high. These conditions may be caused by expected operating characteristics of the new design electro-viscous (EV) fan clutch. This new design EV fan clutch has been installed on production vehicles from the end of 2005 model year production (June 2005) and all 2006 model year vehicles. The new design EV fan clutch may also be present on vehicles serviced with this new part per Corporate Bulletin Number 04-01-38-019A or for other service related conditions. The updated design of the electro-viscous (EV) fan clutch helps improve A/C performance but may also produce some additional fan engagement noise. Important: Unless a specific issue is identified by proper SI diagnosis, do NOT replace a fan clutch for fan noise. Page 1121 Lumbar Adjuster Switch - Driver (w/ Memory) Specifications Page 10352 Abbreviations And Meanings Part 5 Page 5557 Shift Cable: Service and Repair Automatic Transmission Range Selector Cable Bracket Replacement Automatic Transmission Range Selector Cable Bracket Replacement Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Disconnect the transmission range selector cable from the Shift lever and the bracket (2). 5. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. 6. Remove the transmission range selector cable bracket from the vehicle. Installation Procedure 1. Install the transmission range selector cable bracket to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission range selector cable bracket bolts (1). ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 3. Install the transmission range selector cable to the bracket (2) and the lever. 4. Lower the vehicle. 5. Check the vehicle for proper operation. If adjustment of the cable is necessary, refer to Automatic Transmission Range Selector Cable Adjustment. Page 1236 2. Disconnect the electrical connector (2) from the air temperature sensor-upper right (1). 3. Remove the air temperature sensor-upper right (1) by turning the sensor clockwise and pulling out. INSTALLATION PROCEDURE 1. Install the air temperature sensor-upper right (1). 2. Connect the electrical connector (2) to the air temperature sensor-upper right (1). 3. Install the radio. Page 11764 Door Module: Locations Door Lock Switch, Window Switch, Driver Door Module (DDM) Page 7911 Air Spring: Service and Repair Air Spring Replacement Air Spring Replacement Removal Procedure Caution: A sudden release of pressure may cause personal injury or damage to the vehicle. The air suspension system is under pressure until the air supply lines are disconnected. Use the following precautions when servicing the air suspension system: ^ Wear gloves, ear protection, and eye protection. ^ Wrap a clean cloth around the air supply lines. Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensor to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Raise and support the rear axle at the designed D-height. Notice: Depressurize the air suspension system only after the rear axle is supported and is set between D- Height and Full Jounce. 4. Depressurize the air suspension system. Important: There is a raised feature on the outer rim of the air spring top plate that denotes the anti rotation peg position. 5. Depress the antirotation peg (2) in the air spring top plate located in the upper spring seat. 6. With the anti rotation peg (2) depressed, rotate the air spring counterclockwise and remove the air spring from the upper spring seat. 7. Disconnect the air supply line from the air spring in the following way: ^ Push the air supply line into the air spring connection and hold in place. ^ Depress and hold the air supply line collet (2) down. ^ Remove the air supply line (1) from the air spring. Page 6983 Fuse Block - Underhood C6 Page 7082 C104 Part 1 Page 11233 Rear Door Window Regulator: Service and Repair Window Regulator Replacement - Rear Door (TrailBlazer, Envoy, Bravada) Window Regulator Replacement - Rear Door (TrailBlazer, Envoy, Bravada) Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the speaker 4. Loosen the regulator window carrier bolts. 5. Raise and support the window. 6. Disconnect the electrical connector from the regulator motor. 7. Remove the 3 bolts that retain the window regulator assembly to the door. 8. Remove the window regulator assembly from the door. Installation Procedure 1. Install the window regulator assembly to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts that retain the window regulator assembly to the door. Tighten the bolts to 10 N.m (88 lb in). 3. Connect the electrical connector to the regulator motor. 4. Remove the window support and lower the window onto the regulator window carrier. 5. Loosely tighten the regulator window carrier bolts. 6. Operate the window upward to the full up position, ensuring the window remains in the run channels. Tighten the regulator window carrier bolts to 10 N.m (88 lb in). 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Page 10865 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 10333 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 7237 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 7156 4. Install the harness end bolts (2). 5. Install the fuse relay center cover (1) over the relay center bolts. Press downward to engage the tabs. 6. Install the junction block cover. Press downward to engage the tabs. Page 6917 Registered And Non-Registered Trademarks Part 6 Page 7217 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 102 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS DATA Battery Voltage: The scan tool displays the battery system voltage. INPUT Left Rear Door Jamb Switch: The scan tool displays the position of the left rear door. The scan tool displays On when the door is open. Right Rear Door Jamb Switch: The scan tool displays the position of the right rear door. The scan tool displays On when the door is open. Ignition 0: The scan tool displays the position of the ignition switch. The scan tool displays On when the ignition switch is in the Accessory, RUN or CRANK position. Ignition 1: The scan tool displays the position of the ignition switch. The scan tool displays On when the ignition switch is in the Run or Crank position. Ignition 3: The scan tool displays the position of the ignition switch. The scan tool displays On when the ignition switch is in the RUN position only. Ignition Accessory: The scan tool displays the position of the ignition switch. The scan tool displays On when the ignition switch is in the Accessory or RUN position only. Scan Tool Data List Scan Tool Output Controls Page 4440 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield. 3. Remove the electrical connector from the oil pressure switch. 4. Remove the oil pressure switch. Installation Procedure NOTICE: Refer to Fastener Notice in Service Precautions. See: Engine, Cooling and Exhaust/Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the oil pressure switch. Tighten the oil pressure switch to 20 Nm (15 ft. lbs.). 2. Install the electrical connector to the oil pressure switch. 3. Install the engine shield. 4. Lower the vehicle. A/C - Poor Rear Heater Performance Auxiliary Water Pump: Customer Interest A/C - Poor Rear Heater Performance Bulletin No.: 05-01-37-002A Date: November 01, 2005 TECHNICAL Subject: Poor Rear Heat Performance (Install Auxiliary Heater Pump) Models: 2003-2005 Chevrolet TrailBlazer EXT 2003-2005 GMC Envoy XL Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 05-01-37-002 (Section 01 - HVAC). Important: Implementation of this Service Bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on poor 2nd and/or 3rd row seating heater performance when the vehicle is at idle. Cause This condition may be due to lack of coolant circulation to the rear heater core. Correction Install auxiliary heater pump package, P/N 89024885 (L6 Engine RPO LL8) or P/N 89024886 (V8 Engine RPO LM4 or LH6). This pump will improve coolant flow to the rear heater core. Use the procedure listed below. 1. Recover the A/C refrigerant. 2. Drain the cooling system. 3. Disconnect the negative battery cable. 4. Remove the fender rear upper brace. 5. Remove the air cleaner cover. 6. Remove the air cleaner filter element and air outlet duct. 7. Remove the air inlet duct from the lower air cleaner housing/washer solvent tank assembly. 8. Disconnect the washer solvent tank electrical and remove wiring harness from the retaining clips. 9. Disconnect the washer pump hoses and plug the pump outlet ports to prevent loss of washer solvent. 10. Remove the two air cleaner housing/washer tank assembly retaining nuts from the mounting studs. 11. Lift the lower air cleaner housing/washer tank assembly off of the studs and remove the assembly. 12. On the A/C accumulator, disconnect the electrical connector from the low pressure switch. 13. Remove the compressor suction hose assembly from the accumulator. 14. Remove the nut retaining the accumulator to the evaporator. 15. Remove the coolant hoses from the coolant recovery reservoir. Page 5593 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector.Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON transmission fluid. Page 1710 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 386 For vehicles repaired under warranty use, the table. Disclaimer Page 108 Alarm Module: Service and Repair THEFT DETERRENT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. CAUTION: SIR Caution 2. Remove the trim covers. 3. Remove the wire harness straps from the wire harness. 4. Disconnect the connector from the theft deterrent control module. 5. Remove the theft deterrent control module. INSTALLATION PROCEDURE 1. Install the theft deterrent control module. 2. Connect the connector from the theft deterrent control module. 3. Install new wire harness straps to the wire harness assembly. 4. Install the trim covers. 5. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Page 12014 WA519F/12 - WA526F/72 OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 9288 Theft Deterrent Control Module Page 5689 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Page 2785 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 12796 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 10656 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 9395 Registered And Non-Registered Trademarks Part 3 Page 1914 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 11139 3. Using the line from the china marker (4) as a guide and starting at the sill plate, install the seal along the rear rocker panel with seal bulb (2) toward the door. Flatten the bulb and align it to the china marker line pressing lightly. 4. Close the door and check for the gasket pushing out between the door and the body. 5. If the gasket was pushing out, realign the gasket in that area. 6. Trim the gasket so that it does not extend higher than the rocker panel (5) as necessary. 7. When the gasket is located, open the door and firmly press the gasket into place. A roller tool may be helpful in seating the gasket. 8. Check the door latch for proper operation: 8.1. Open the rear door. 8.2. Open the rear side closure. 8.3. Listen for two audible clicks while rotating the fork bolt from the full open to the fully latched position. 9. If two distinct audible clicks are NOT heard: Page 2891 Page 10913 Body Control Module: Removal and Replacement Body Control Module Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the BCM on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. Page 2283 4. Install the harness end bolts (2). 5. Install the fuse relay center cover (1) over the relay center bolts. Press downward to engage the tabs. 6. Install the junction block cover. Press downward to engage the tabs. Page 7536 Relay Box: Service and Repair Rear Electrical Center or Junction Block Replacement REAR ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a cargo position. 4. Remove the rear electrical center cover. 5. Remove the battery feed terminal nut (2) from the junction block. 6. Remove the body control module (BCM) from the rear electrical center. 7. Fully loosen the 3 bolts (1) that retain the junction block to the electrical connectors. Page 12867 Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front .................................................................................................................................................... .......................................................... 0.8L (2.6 Pints) Rear ................................................................ ............................................................................................................................................... 1.9L (4.0 Pints) Rear with 8.6" Ring Gear ................................................................................................... ........................................................................... 2.2L (4.8 Pints) Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 6987 Application Table Part 1 OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Transmission Fluid Cooler Hose/Pipe Replace-Body VIN Code 3 LL8 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replace-Body VIN Code 3 LL8 Transmission Fluid Cooler Hose/Pipe Replacement (Body Vin Code 3 LL8) Removal Procedure 1. Disconnect the transmission cooler lines from the radiator. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Place a drain pan under the vehicle. 4. Remove the cooler lines (3, 4) from the radiator. 5. Separate the front and rear cooler lines at the quick connect fitting (2). 6. Remove the cooler lines from the retainer (1) located on the radiator shroud. 7. Remove the front sections of the cooler lines from the vehicle. 8. Remove the rear sections of the cooler lines from the retainer (1) located on the right side of the engine. 9. Remove the clip (2) that holds the cooler lines together. 10. Support the transmission with a transmission jack. 11. Remove the transmission support. 12. Remove the front exhaust pipe assembly. 13. Carefully lower the transmission to gain access to the cooler line fittings. 14. Disconnect the transmission cooler lines from the transmission. Page 2825 Abbreviations And Meanings Part 23 Page 10362 Abbreviations And Meanings Part 15 Page 5188 Accumulator: Service and Repair Accumulator Assembly, Spacer Plate, and Gaskets ^ Tools Required J 25025-B Pump and Valve Body Alignment Pin Set - J 36850 Transjel/Lubricant Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. Important: The 1-2 accumulator can be removed without removing the control valve assembly. 3. Remove the control valve body. 4. Remove the accumulator cover retaining bolts. 5. Remove the 1-2 accumulator cover assembly. 6. Disassemble the 1-2 accumulator. 6.1. Blow compressed air into the 1-2 accumulator cover, as shown, to remove the 1-2 accumulator piston. 6.2. Remove the 1-2 accumulator inner and outer springs. 7. Inspect the 1-2 accumulator inner and outer springs for cracks. Page 10515 Page 9547 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 10671 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 1971 Drive Belt Squeal Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt(s) or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. 5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Drive Belt Vibration Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Page 10128 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 7109 C309 (Long Wheelbase, Body Type VIN 6) Part 2 C310 Page 13919 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 13643 License Plate Lamp: Description and Operation PARK, TAIL, MARKER, LICENSE, AND CLEARANCE LAMPS The park, tail, marker, license, and clearance (Y92 only) lamps are turned on when the headlamp switch is placed in the PARK or ON position or anytime the headlights are requested. The I/P BATT fuse in the engine wiring harness junction block supplies battery positive voltage to both the park lamp relay switch contacts and the park lamp coil circuit. The body control module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the park lamps are turned on, the BCM energizes the park lamp relay. Current flow is from the park lamp relay to the individual park lamp circuit fuses and to their respective park, tail, marker, and license lamps. The front park and marker lamps are grounded at G107 and G103. The tail lamps are grounded at G401 and G402. The license lamps are grounded at G401. When equipped with the Y92 roof rack option, the clearance lamps are grounded at G302. If the driver places the headlight switch in the ON position after the ignition switch has been turned OFF, the park, tail, marker, license, and clearance lamps will remain on until turned off or the battery runs dead. The T PARK fuse in the rear fuse-relay block supplies battery positive voltage to a separate park lamp circuit connected to the trailer wiring harness. Page 9443 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 4272 Abbreviations And Meanings Part 6 Page 12824 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 12072 WA8555/41 - WA8555/41 Page 13112 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Interior - Cargo Cover Handle is Broken Cargo Cover: All Technical Service Bulletins Interior - Cargo Cover Handle is Broken Bulletin No.: 05-08-110-004A Date: May 02, 2006 TECHNICAL Subject: Cargo Cover Handle Broken (Replace Cargo Cover Handle - Service Part Available) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add the 2006 model year and the Saab 9-7X model information. Please discard Corporate Bulletin Number 05-08-110-004 (Section 08 - Body & Accessories). Condition Some customers may comment that the cargo cover handle is broken. Part returns have shown that the handle may be fractured at the locating pins. Correction DO NOT REPLACE THE CARGO COVER. Use the following steps the replace the cargo cover handle: 1. Using a flat-bladed tool, depress the two tabs that retain the handle to the cargo cover. 2. Remove the handle from the cargo cover. 3. Install the new handle to the cargo cover. Be sure that the two retaining tabs are released to secure the handle in position. Parts Information Page 2066 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Fuel System - Fuel Spit-Back/Early Pump Nozzle Shut-Off Fuel Filler Hose: All Technical Service Bulletins Fuel System - Fuel Spit-Back/Early Pump Nozzle Shut-Off Bulletin No.: 04-06-04-003A Date: August 11, 2004 TECHNICAL Subject: Vehicle is Difficult to Fill with Fuel or Filling Station Pump Shuts Off Before Tank is Full or Fuel Spits Back/Out When Filling Tank (Replace Fuel Tank Filler Upper Pipe and Lower Hose) Models: 2003 Chevrolet TrailBlazer with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2003 GMC Envoy with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2003 Oldsmobile Bravada with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL 2004 Buick Rainier 2004 Chevrolet TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Envoy XUV 2004 Oldsmobile Bravada Built Prior to December 2003 Supercede: This bulletin is being revised to provide new part number for 2002-2003 vehicles. Please discard Corporate Bulletin Number 04-06-04-003 (Section 06 - Engine/Propulsion System). This bulletin provides information on two different conditions. Condition 1 Some customers may comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. Cause This condition may be caused by the variability (fuel flow rates, type of fuel fill nozzle, fuel properties) at the filling stations. There is a potential to develop an increase in back pressures internal to the fuel fill neck. This back pressure trips the fuel nozzle prior to filling the tank, or results in a hard to fill condition. Condition 2 Some customers may comment that when filling the fuel tank, a small amount of fuel may spit back/out. Cause This condition may be caused by the equalization of pressure between the fuel tank and the fuel fill neck that does not react quickly to the variance in the pressure when the fueling station fuel nozzle trips off. Correction Replace the fuel tank filler upper pipe assembly with P/N 88983256 or P/N 15131043, and lower hose assembly with P/N 15131046. The new upper pipe has been redesigned to provide smoother flow conditions within the section and the lower hose has been redesigned to include a checking feature. Use the procedure listed below. 1. Remove the fuel fill cap. 2. Remove the fuel fill pipe housing. Page 6998 Application Table Part 3 Engine/Transmission - Flexplate/Flywheel Replacement Flywheel: Technical Service Bulletins Engine/Transmission - Flexplate/Flywheel Replacement File In Section: 06 - Engine/Propulsion System Bulletin No.: 03-06-01-003 Date: February, 2003 INFORMATION Subject: Flywheel/Flexplate Replacement Models: 2003 Passenger Cars and Light Trucks When replacing the starter for any reason, the flywheel/flexplate should be inspected before replacement. The flywheel/flexplate should be turned a full 360 degrees and inspected for missing or broken teeth or signs of starter milling on the sides of the teeth before replacement. No flywheel/flexplate should be replaced without a visual defect. The majority of flywheel/flexplates returned to GM after replacement under warranty show no signs of damage or defect. Disclaimer Page 7141 Relay Box: Service and Repair Rear Electrical Center or Junction Block Replacement REAR ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a cargo position. 4. Remove the rear electrical center cover. 5. Remove the battery feed terminal nut (2) from the junction block. 6. Remove the body control module (BCM) from the rear electrical center. 7. Fully loosen the 3 bolts (1) that retain the junction block to the electrical connectors. Page 4320 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). 7. Disconnect the body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. Page 1478 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 11785 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 2889 Page 5106 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 9804 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 6978 Fuse Block - Underhood C3 Part 3 Page 10977 Rear Bumper Reinforcement: Service and Repair Impact Bar Replacement - Rear Bumper Removal Procedure 1. Remove the spare tire carrier. 2. Remove the rear fascia. 3. Disconnect the trailer/towing receptacle electrical connector. 4. Rotate the trailer/towing receptacle assembly counterclockwise and remove from the vehicle. 5. Remove the 4 rearward bolts that retain the impact bar assembly to the frame rails. 6. While an assistant holds the impact bar (1) assembly in place, remove the remaining 2 retaining bolts. 7. Remove the impact bar (1) assembly from the vehicle with an assistant. Installation Procedure 1. Position the impact bar (1) assembly to the vehicle with an assistant. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the rear impact bar to the frame. Tighten the rear impact bar bolts to 364 N.m (268 lb ft). Locations Engine, Left Side Page 13244 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Entertainment System - DVD Monitor Display Inoperative Television / Monitor: All Technical Service Bulletins Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Page 6910 Abbreviations And Meanings Part 25 Master Cylinder Bench Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11 GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11 GM U.S. P/N 12377967, GM Canada P/N 992667, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 2797 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 13048 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Access IP module connector through glove box. 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 6160 Page 7376 Application Table Part 2 Page 2940 Abbreviations And Meanings Part 12 Page 12522 Various symbols in order to describe different service operations. Locations Page 7093 C201 Part 5 Page 628 Mirror Switch, Driver Door Module (DDM) - C5 Page 11072 For 2007 vehicles repaired under warranty, use the table. Disclaimer Page 10965 4. Position the fascia support rods (2) to the impact bar (5). 5. Install the bolts (2) which retain the fascia support rods to the impact bar. Tighten the bolts to 10 N.m (89 lb in). 6. Install the front fascia. Page 1442 Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). Page 6402 5. Release the wiring harness from the retaining clips (2) on the frame and reposition the harness as necessary to allow for removal of the brake pipe. 6. Disconnect the wheel speed sensor harness connector (1) located on the outboard side of the left frame rail near the front caliper brake hose fitting. 7. From the left front wheelhouse, remove the brake pipe from the vehicle. 8. Position the new brake pipe to the vehicle and install it in the retainers on the frame. Notice To avoid damaging the threads on the ABS modulator, flare nuts, or the front brake hose fitting, use only your fingers to start the threads. Do not use tools to start threading the flare nut into the ABS modulator or the front brake hose fitting. 9. Connect the brake pipe to the ABS modulator and tighten the flare nut. Tighten to 20 N.m (15 lb ft). 10. Connect the brake pipe to the left front caliper brake hose fitting. Tighten lighten the flare nut to 20 N.m (15 lb ft). 11. Position the wiring harness to the frame and secure in the retainers. 12. Connect the wheel speed sensor harness connector. Important Do not drive the vehicle until the brake pedal feels firm. Do not reuse brake fluid that is used during bleeding. 13. Lower the vehicle as necessary to allow for manual bleeding of the left front brake assembly. Caution Refer to Brake Fluid Caution in the Cautions and Notices in the appropriate Service Manual. Notice Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices in the appropriate Service Manual. Notice When adding fluid to the brake master cylinder reservoir, use only DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination, which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Important Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm in the next step. 14. Fill the brake master cylinder reservoir with Delco Supreme 11(R), GM P/N 12377967, Canadian P/N 89021320, or equivalent DOT-3 brake fluid from a clean sealed brake fluid container. 15. Install the J 35589-A to the brake master cylinder reservoir. 16. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme 11(R) or equivalent DOT-3 brake fluid from a clean sealed brake fluid container as necessary to bring the level to approximately the half-full point. 17. Connect the J 29532, or equivalent, to the J 35589-A. 18. Charge the J 29532, or equivalent, air tank to 175-205 kPa (25-30 psi). 19. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Specifications Oil Pressure Sensor: Specifications Oil Pressure Sensor 15 ft. lbs. Page 5179 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install TCC PWM solenoid retainer. Page 12391 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Part 1 Specifications Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Mounting Bolt 12 ft. lbs. Lighting - Center Mounted Stop Lamp Applique loose Center Mounted Brake Lamp: Customer Interest Lighting - Center Mounted Stop Lamp Applique loose Bulletin No.: 05-08-111-006B Date: April 10, 2006 TECHNICAL Subject: Rear Center High Mounted Stop Lamp (CHMSL) Applique Sealing Strip Loose (Repair or Replace Sealing Strip) Models: 2003-2006 Chevrolet TrailBlazer EXT 2003-2006 GMC Envoy XL Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 05-08-111-006A (Section 08 - Body and Accessories). Condition Some customers may comment that the sealing strip has come loose from the CHMSL applique. Correction If the seal is not damaged, the seal can be cleaned and reinstalled with some weatherstrip adhesive. If the seal is damaged or missing, replace the seal with the applicable seal part number below. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 11174 Page 8411 Registered And Non-Registered Trademarks Part 5 Locations Memory/Heated Seat Switches Page 7677 Power Steering Pump: Service and Repair Power Steering Pump Replacement Power Steering Pump-Replacement Removal Procedure 1. Remove the radiator air intake baffle. 2. Remove the air cleaner assembly. 3. Remove the drive belt. 4. Install a drain pan under the vehicle. 5. Disconnect the power steering pressure hose (1) from the power steering pump. 6. Disconnect the power steering cooler hose (2) from the power steering pump. 7. Disconnect the wiring harness from the wiring loom on the power steering pump. 8. Remove the power steering pump mounting bolts. 9. Remove the power steering pump. 10. Remove the power steering pump pulley. Installation Procedure 1. Install the power steering pump pulley. Notice: Refer to Fastener Notice in Service Precautions. Page 9995 Page 7613 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment The caster and camber adjustments are made by loosening the lower control arm adjustment bolts and repositioning the lower control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. - Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension and the rear suspension D dimension are indicated in Trim Heights. 1. For an accurate reading, do not push or pull on the tires during the alignment process. View Of Left Front Wheel From Left Side Of Vehicle 2. Determine the caster angle. View Of Front Wheel From Front Of Vehicle 3. Determine the camber angle. Page 2478 Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Page 10208 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 9442 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 11673 Rear. 26. Install the video display. 27. Attach the mechanic's wire to the end of the headliner harness positioned behind the IP. 28. Pull the bottom of the mechanic's wire away from the cowl insulation access hole in order to position the headliner harness behind the IP. 29. Attach the 3 clips (1) securing the wire harness to the windshield pillar. 30. Attach the lower rosebud (2) retaining the headliner harness to the cowl. 31. Connect the coax cable (2) and headliner harness connector (1). 32. Close the IP compartment door. 33. Install the right sound insulator. 34. Install the IP trim pad. 35. Install the windshield garnish moldings. 36. Install the center pillar trim panels. 37. Install the rear side door sill plates. 38. Install the front side door sill plates. 39. Install the rear seats. 40. Install the luggage/cargo shelf assembly, if equipped. 41. Install the cargo net, if equipped. Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 2665 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Install 3/3 inch breaker bar on the drive belt tensioner arm and turn the breaker bar clockwise enough to relieve the tension on the drivebelt. 2. Remove the drivebelt. 3. Release the tension on the tensioner arm. Installation Procedure 1. Route the drivebelt over all the pulleys except the drivebelt tensioner pulley. 2. Install the 3/8 inch breaker bar on the drivebelt tensioner arm and turn the breaker bar clockwise. 3. Install the drivebelt over the drivebelt tensioner pulley. 4. Slowly release the tension to the drivebelt tensioner arm. 5. Inspect for proper installation of the drivebelt on the pulleys. Page 11242 Hood Hinge: Service and Repair Fender Rail Hood Hinge Bracket Replacement - Upper Fender Rail Hood Hinge Bracket Replacement - Upper Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution in Service Precautions. 1. Remove all of the related panels and components. 2. Restore as much of the damage as possible to the factory specifications. 3. Note the location and remove the following as necessary: * The sealers * The sound deadeners * The anti-corrosion materials Important: Drill through the hinge bracket only. 4. Locate, and drill out all of the factory welds for installation of the service part. Important: Do not damage any of the inner panels or reinforcements. 5. Remove the damaged hood hinge bracket. Installation Procedure Page 6061 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 4126 Abbreviations And Meanings Part 12 Page 11836 Abbreviations And Meanings Part 21 Page 13514 Courtesy/Reading Lamp - Left Center (Body Type VIN 6) Page 9401 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION DRIVER INFORMATION CENTER (DIC) The driver information center (DIC) consists of a single line 22 character vacuum fluorescent (VF) display placed in the lower center area of the instrument panel cluster (IPC). The DIC will display vehicle information, configuration, and warning parameters to the driver. The display parameters are cycled, changed, and acknowledged using four (4) DIC buttons. Trip Information Button representation icon appears as a road to the horizon. - Fuel Information Button representation icon appears as a gasoline pump. - Personalization Button representation icon appears as a human next to vehicle. - Select Button representation icon appears as an arrow. DIC DISPLAYS The DIC parameters are displayed by order of priority as follows (from highest to lowest) : Service Diagnostics - Driver Identifier - Feature Programming - Driver Warnings - Vehicle Information VEHICLE INFORMATION Vehicle information provides feedback to the driver on vehicle performance, mileage, maintenance, or related information. Vehicle information can only be displayed with the ignition switch in the RUN position. When the English/Metric status changes, any applicable vehicle information data values will also change. DIC TRIP INFORMATION / RESET CAPABILITIES The available DIC Trip Information and reset capabilities are as follows: Odometer - Cannot be reset - Trip Odometer A - Can be reset - Trip Odometer B - Can be reset - Timer - Can be reset TRIP RESET STEM The trip reset stem on the IPC operates in the following manner with the ignition switch in the RUN position: 1. Each time the reset stem or SWC Select button is pushed the display will cycle to the next trip parameter. The trip parameters are as follows: - Odometer - Trip A odometer - Trip B odometer 2. Holding the reset stem for greater than 3 seconds or depressing the SWC Select button while either Trip A or Trip B odometer is displayed will reset the displayed trip odometer to 0.0 upon release of the stem. The trip odometer will remain displayed after being reset. 3. If a trip odometer parameter is being displayed, pressing the DIC Trip Information button will display the next trip odometer parameter. 4. If the next Trip Information parameter to be displayed is Timer or blank, pressing the reset stem will return the display to the Odometer. ODOMETER The odometer is capable of displaying values from 0 to 999,999 MI or KM. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip reset stem. The odometer will remain displayed for 5 seconds. TRIP ODOMETERS The DIC can display Trip A or Trip B odometers. The trip odometers are capable of displaying values from 0 to 9999.9 MI or KM. When the maximum value is reached, the trip odometer will roll over to 0.0. TIMER The Timer is displayed as XX (hours) : XX (minutes) : XX (seconds). Page 6292 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Page 13856 Vanity Lamp: Service and Repair VANITY MIRROR LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Fold down the sunshade. 2. Open the cover to the vanity mirror in order to reveal the vanity light. 3. Use a flat bladed tool in order to release the retaining tab on the vanity light lens. 4. Remove the vanity light lens from the vanity mirror. 5. Remove the bulb from the socket. INSTALLATION PROCEDURE 1. Install the bulb to the socket. 2. Install the vanity light lens to the vanity mirror ensuring the retaining tab is fully seated. 3. Close the cover to the vanity mirror. 4. Return the sunshade to the folded up position. Page 6680 Abbreviations And Meanings Part 2 HVAC System - Manual Blower Motor Switch: Service and Repair HVAC System - Manual FRONT AUXILIARY BLOWER MOTOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Press downward and to the right on the front auxiliary blower motor switch. 2. Remove the front auxiliary blower motor switch from the console. 3. Disconnect the electrical connector from the front auxiliary blower motor switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the front auxiliary blower motor switch. 2. Install the front auxiliary blower motor switch to console. 3. Press the front auxiliary blower motor switch into the console. Page 10347 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 12507 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Locations Seat Belt Buckle Page 4544 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 11885 Door Lock Actuator - Liftgate Locations Page 8931 1.2. Align the block tooth and the centering mark on the race and upper shaft assembly at the 12 o'clock position. 2. If centering is required, follow the instructions on the notice (1) of the coil assembly. Refer to Inflatable Restraint Steering Wheel Module Coil Centering in Steering Wheel and Column. IMPORTANT: The new SIR coil will be pre-centered. Do not remove the centering tab from the new SIR coil until the installation is complete. If the SIR coil does not come with a centering tab, you must center the SIR coil. 3. Align the SIR coil assembly (1) with the horn tower on the turn signal cancel cam assembly (2). 4. Slide the new SIR coil (4) onto the steering shaft assembly (2). Page 12430 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Page 2923 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 736 For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Electrical Frontal Sensor Impact Sensor: Diagrams Electrical Frontal Sensor Electronic Frontal Sensor - Left Page 10862 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 5661 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6260 Brake Caliper: Service and Repair Brake Caliper Replacement Front Brake Caliper Replacement- Front Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the front brake hose bolt. 4. Install a plug in the front brake caliper hose in order to prevent excessive brake fluid loss and contamination. 5. Discard the metal/copper gaskets. DO NOT reuse them replace with NEW metal/copper gaskets. 6. Remove the front brake caliper mounting bolts. 7. Remove the front brake caliper from the mounting bracket. Installation Procedure Page 11566 There may be a lack of sealer under the "A" pillar reveal molding push nuts. Refer to the illustration above. Cause 4 The push-in retainers at the base of the auxiliary weatherstrip may not be seated fully. Refer to the illustration above. Cause 5 There may be a gap between the many pieces of sheet metal under the primary seal flange. If this is present, water may enter under the primary seal retainer and into the vehicle between the gaps in the sheet metal flange and end up under the carpet. Refer to the illustration above. Correction 1 Page 10559 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 2718 Engine Oil: Description and Operation Api Oil and Additives WHAT KIND OF ENGINE OIL TO USE Oils recommended for your vehicle can be identified by looking for the starburst symbol. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). Do not use any oil which does not carry this starburst symbol. If you choose to perform the engine oil change service yourself, be sure the oil you use has the starburst symbol on the front of the oil container. If you have your oil changed for you, be sure the oil put into your engine is American Petroleum Institute certified for gasoline engines. You should also use the proper viscosity oil for your vehicle, as shown in the viscosity chart. As in the chart shown previously, SAE 5W-30 is the only viscosity grade recommended for your vehicle. You should look for and use only oils which have the API Starburst symbol and which are also identified as SAE 5W-30. If you cannot find such SAE 5W-30 oils, you can use an SAE 10W-30 oil which has the API Starburst symbol, if it's going to be 0°F (-18°C) or above. Do not use other viscosity grade oils, such as SAE 10W-40 or SAE 20W-50 under any conditions. NOTICE: Use only engine oil with the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench® oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. ENGINE OIL ADDITIVES Don't add anything to your oil. The recommended oils with the starburst symbol are all you will need for good performance and engine protection. Page 879 Abbreviations And Meanings Part 24 Page 1778 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle INSTALLATION PROCEDURE 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. 4. If replacing the driver door module, program the driver door module. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming and Personalization Description and Operation in Personalization. IMPORTANT: When replacing the driver door module, the set up procedure must be performed. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 7970 1. Install the rear coil springs. 2. Raise the rear axle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the shock absorber lower mounting bolts. Tighten the shock absorber lower mounting bolts to 80 Nm (59 ft. lbs.). 4. Remove the rear axle support. 5. Lower the vehicle. Page 9352 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 2659 Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Drive Belt Excessive Wear Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Page 8658 Housing Assembly HVAC: Service and Repair HVAC Module Assembly Replacement - Auxiliary HVAC MODULE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Drain the cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6) Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the nuts (3) from rear A/C line block fittings. 5. Remove the A/C line block fittings and discard the O-ring seals. IMPORTANT:Cap or tape the open A/C refrigerant lines immediately. 6. Remove the nuts from the heater hoses block fittings. 7. Remove the heater hoses block fittings from the HVAC module-auxiliary. 8. Remove the nuts from the HVAC module studs. 9. Lower the vehicle. 10. Remove the right side rear quarter trim. Page 627 Memory Seat Switch, Driver Door Module (DDM) - C4 Body - Door(s) Are Difficult To Close Front Door Striker: All Technical Service Bulletins Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Page 3611 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE 1. Install the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Page 12993 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 12602 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle Installation Procedure 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. Important: When replacing the driver door module, the set up procedure must be performed. 4. If replacing the driver door module, program the driver door module. Refer to Service Programming System (SPS) (Remote Procedure) Service Programming System (SPS) (Pass-Thru Procedure) Service Programming System (SPS) (Off Board Remote Procedure) Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming and Personalization Description and Operation in Personalization. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Switch Replacement - Door Lock and Side Window - Passenger Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure Page 12443 10. Separate the hook and loop retaining strips. IMPORTANT: When separating the seat cover hook and loop retaining strips, do not pull the adhesive-backed strip from the seat pad. 11. Remove the hog rings (1) from the bottom rear side of the cover. 12. Remove the 11 hog rings from the top side of the cover. 13. Remove the seat cushion trim cover and pad from the seat frame. 14. Remove the seat module retaining screw, if equipped. 15. Remove the seat module, if equipped. 16. Remove the seat cover from the seat cushion. 17. Remove the seat cushion from the seat pan. INSTALLATION PROCEDURE 1. Install the seat cushion to the seat pan. 2. Install the seat cover to the seat cushion. 3. Using a side to side motion, carefully pull the seat cushion cover onto the seat pan. Page 1660 For vehicles repaired under warranty, use the table. Disclaimer Page 13295 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 4626 Steps 3-8 Page 10179 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 6921 Auxiliary Power Outlet - Rear Page 12042 WA9539/47 - WA9792/39 Page 10060 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 6039 Disclaimer Page 5312 Tip: It is necessary to remove the two A/C line (suction line / low side of muffler hose) retainers and reposition the A/C line to allow proper clearance for installation of the new transmission fluid fill tube. 5. Remove the A/C line at the oil level indicator tube bracket nut. 6. Remove the A/C bracket bolt from the engine lift hook. 7. Reposition the A/C line upward. 8. Install the new transmission filler tube, P/N 15000220, into position but NOT into the transmission at this time. 9. Raise the vehicle. 10. Remove the two bolts securing the transmission heat shield to the transmission. 11. Remove the transmission heat shield from the transmission. 12. Remove the old filler tube seal from the transmission case. 13. Install a new seal, P/N 1259475 into the transmission case. 14. Position the new transmission filler tube into the transmission seal. 15. Install the transmission heat shield to the transmission. 16. Install the two bolts securing the transmission heat shield to the transmission. Tighten Tighten the bolts to 17 N.m (13 lb ft). 17. Lower the vehicle. 18. Install the nut securing the filler tube to the stud. Tighten Page 1034 For Canada & IPC: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. PARTS INFORMATION Parts Pre-Ship Information - For US and Canada Important: An initial supply of windshield wiper transmission seal assemblies required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of June 28, 2004 and will be approximately 20% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. CUSTOMER REIMBURSEMENT - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Product Recall Customer Reimbursement Procedure Form is included with the customer letter. IMPORTANT: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. CUSTOMER REIMBURSEMENT - For Canada Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted by July 31, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. IMPORTANT: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period Page 3875 Page 4807 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 8010 The rear end lift points for the floor jack are at the following locations: - Beneath the axle housing, inboard from the shock absorber mounts - Beneath the axle differential Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: - Chock the wheels at the end of the vehicle opposite the end being lifted - Use jack stands for support. Place jack stands at the any of the following locations: - Beneath the frame - Beneath the front suspension crossmember - Beneath the axle When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. NOTE: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: - The catalytic converter - The brake lines - The brake cables - The fuel lines - The accelerator cables - The transmission shift cables Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 2816 Abbreviations And Meanings Part 14 Page 12257 Sunroof / Moonroof Module: Diagrams Sunroof Module C1 Page 6595 For vehicles repaired under warranty, use the table. Disclaimer Page 6303 1. Install the brake rotor to the wheel hub. 2. Install the brake caliper assembly to the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the brake caliper mounting bolt. ^ Tighten the brake caliper bracket mounting bolt to 150 Nm (110 ft. lbs.). 4. Install the tire and wheel assembly. 5. Lower the vehicle. Refer to Vehicle Lifting. 6. Fill the brake master cylinder to the proper level. Caution: Refer to Firm Brake Pedal Caution in Service Precautions. 7. Pump the brake pedal slowly and firmly in order to seat the brake pads. 8. Burnish the replaced or refinished rotors. Rear Page 9969 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 2553 Warranty Information Page 4227 A/C - Non-Programmable Control Heads Control Assembly: All Technical Service Bulletins A/C - Non-Programmable Control Heads File In Section: 01 - HVAC Bulletin No.: 03-01-38-003 Date: April, 2003 INFORMATION Subject: Certain HVAC Control Heads Not Reprogrammable Models: 2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 GMC Envoy, Envoy XL 2003 Oldsmobile Bravada This bulletin is being issued to alert technicians that a heating, ventilation and air conditioning (HVAC) control head was used in production vehicles that can be programmed only one time. The control head was used in vehicles with both manual (0J3) and automatic (CJ2) HVAC systems produced between mid October 2002 through early January 2003. The HVAC control head used during this period cannot be reprogrammed using TIS 2000. The HVAC module part numbers as seen on the Tech2(R) are 15202099, 15202100, 15202101 and 15202102. A message will appear on the TIS 2000 screen with a warning not to reprogram these part number modules. If a technician attempts to reprogram this module, the module will lock up and become totally non-functional. These modules already have an updated calibration to address the issues mentioned in Corporate Bulletin Number 02-01-39-005. All HVAC control heads received from GMSPO for service replacement are a different part number and they are reprogrammable. Disclaimer Page 12380 Power Seat Motor: Service and Repair Seat Adjuster Mechanism Replacement - Power Removal Procedure 1. Remove the front bucket seat assembly from the vehicle. 2. Remove the seat cushion trim panel. 3. Remove the seat belt buckle nut. 4. Disconnect the black electrical connector (6) from the seat back harness. 5. Disconnect the black electrical connector (3) from the seat belt buckle. 6. Disconnect the gray lumbar electrical connector (5), if equipped. 7. Remove the SIR harness (2) from the harness clips (1,4), and remove the SIR harness from the seat. 8. Remove the 4 nuts that secure the seat pan to the power seat adjuster frame. 9. Remove the seat back. Installation Procedure Page 12700 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 3277 5. Using the J 46406 to secure the water pump pulley, install the fan nut to the water pump shaft in a clockwise rotation. Tighten the fan hub nut to 56 Nm (41 ft. lbs.). 6. Install the transmission cooler lines to the engine and clip into the fan shroud. 7. Install the hood latch support. 8. Install the upper inlet radiator hose to the radiator. 9. Reposition the upper inlet radiator hose clamp using J 38185. 10. Install the air intake baffle. Page 13866 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 8379 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 275 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 3493 Abbreviations And Meanings Part 10 Page 4031 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 1385 operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. 2. Install the ECT sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. Page 7522 12. Disconnect the body wiring harness connector (1) from the junction block. 13. Disconnect the headliner harness connector (2) from the junction block. 14. Disconnect the console harness connector from the junction block. 15. Remove the block base retaining nuts from the floor studs. 16. Remove the block base from the floor panel. INSTALLATION PROCEDURE 1. Install the block base to the floor studs. 2. Install the block base retaining nuts to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the block base retaining nuts to 10 N.m (88 lb in). 3. Connect the console harness connector to the block base. 4. Connect the headliner harness connector (2) to the block base. 5. Connect the body wiring harness connector (1) to the block base. Description and Operation Fuel Rail: Description and Operation FUEL RAIL ASSEMBLY The fuel rail assembly attaches to the cylinder head. The fuel rail assembly performs the following functions: - Positions the fuel injectors in the cylinder head - Distributes fuel evenly to the injectors - Integrates the fuel pressure regulator into the fuel metering system Page 8491 Lower Console (w/Manual - HVAC System) (Body Type VIN 6) Page 12027 WA813K/89 - WA817K/63 Page 12477 1. Remove the two rear seat cushion bolts (2) securing the rear seat cushion assembly (1) to the seat latch rod (3). 2. Remove the seat cushion assembly. 3. Remove the pull handle (1). 4. Remove the J-strips (2) securing the seat cushion cover to the seat cushion panel. 5. Remove the seat cushion panel from the pad and cover. Installation Procedure 1. Install the seat cushion panel on the pad and cover. 2. Install the J-strips (2) securing the seat cushion cover to the seat cushion panel. 3. Install the pull handle (1). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the rear seat cushion assembly (1) to the seat latch rod (3) with two rear seat cushion bolts (2). Tighten the rear seat cushion bolts to 11 N.m (97 lb in). Seat Cushion Trim Panel Replacement - Rear No.1 (TrailBlazer EXT, Envoy XL) Seat Cushion Trim Panel Replacement - Rear No.1 (TrailBlazer EXT, Envoy XL) Removal Procedure 1. Remove the seat from the vehicle. Page 12119 Page 147 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 12404 Seat Adjuster Switch - Passenger (w/o Heat) Part 2 Page 668 Memory Seat Module - Passenger C3 Part 2 Page 7448 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 11814 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 7112 C312 Part 2 Page 10023 Page 10389 Steps 7-12 Page 13159 Registered And Non-Registered Trademarks Part 5 Page 6156 Page 9030 Seat Belt: Service and Repair Lower Anchor Assembly - Rear No. 1 (TrailBlazer EXT, Envoy XL) REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the trim panel from the seat cushion. 3. Remove the bolt (2) securing the lower anchor (1) to the seat cushion frame. 4. Remove the lower anchor. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the rear seat lower anchor to the seat cushion frame with the bolt (2). Tighten Tighten the rear seat lower anchor bolt to 35 N.m (26 lb ft). 2. Install the trim panel to the seat cushion. 3. Install the seat in the vehicle. Page 12811 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 11854 Memory Seat Switch, Driver Door Module (DDM) - C4 Page 5828 21. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 22. Install the differential. 23. Perform a gear tooth contact pattern check on the pinion and the ring gear. 24. Install the axle shafts. 25. Install the brake rotors. 26. Install the brake calipers. 27. Install the tire and wheel assemblies. 28. Fill the axle with axle lubricant. Use the proper fluid. 29. Lower the vehicle. Page 1177 Page 2772 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 6758 Page 10305 Page 9430 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 4730 3. Remove the fuel fill pipe bracket nut (2). 4. Raise and suitably support the vehicle. 5. Remove the fuel fill pipe ground strap bolt. 6. Cut off the ground strap ring terminal and tie strap. 7. Loosen the fuel hose clamp (8). 8. Remove the fuel fill upper pipe (7) from the vehicle. 9. Install the new fuel fill upper pipe into the vehicle. Use P/N 88983256 for 2002-2003 model year vehicles or P/N 15131043 for 2004 model year vehicles. 10. Tighten the fuel hose clamp. Tighten Tighten the clamp to 2.5 N.m (22 lb in). 11. Wrap the excess length of ground strap around the fuel hose as necessary. 12. Install the fuel fill pipe ground strap bolt in its original location. 13. Loosen the fuel hose clamps (1, 3). 14. Remove the lower fuel hose (2) from the vehicle. 15. Install the new lower fuel hose into the vehicle. 16. Tighten the lower fuel hose clamps. Tighten Page 6782 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 13408 Please follow the instructions on the Claim Form to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Service Procedure 1. Open the rear liftgate. 2. Remove the two screws that attach both the left and right tail lamp assemblies and remove the lamps from the body. 3. Inspect the part number on both the left and right tail lamp circuit boards. Chevrolet -- New P/N 16532713 Chevrolet Export -- New P/N Steering - Steering Gear Stub Shaft Bearing Kit Steering Gear: All Technical Service Bulletins Steering - Steering Gear Stub Shaft Bearing Kit INFORMATION Bulletin No.: 04-02-32-001F Date: December 02, 2009 Subject: Release of Steering Gear Stub Shaft Bearing Kit for Service Models: 2002-2005 Buick Century, LeSabre, Park Avenue, Regal 2002-2007 Buick Rendezvous 2004-2007 Buick Rainier 2005-2007 Buick Buick Allure (Canada), LaCrosse, Terraza 2002-2005 Chevrolet Cavalier, Impala, Malibu Classic, Venture 2002-2007 Chevrolet Monte Carlo 2002-2009 Chevrolet TrailBlazer 2003-2010 Chevrolet Express 2004-2007 Chevrolet Silverado (2WD) (Classic) 1500 Series 2005-2009 Chevrolet Uplander 2002-2009 GMC Envoy Models 2003-2007 GMC Sierra (2WD) (Classic) 1500 Series 2003-2010 GMC Savana 2002-2003 Oldsmobile Bravada 2002-2004 Oldsmobile Alero, Silhouette 2002-2004 Pontiac Aztek 2002-2005 Pontiac Bonneville, Grand Am, Montana, Sunfire 2002-2008 Pontiac Grand Prix (Excluding GTP Models) 2005-2009 Pontiac Montana SV6 2005-2007 Saturn RELAY 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the information. Please discard Corporate Bulletin Number 04-02-32-001E (Section 02 - Steering). GMSPO has released a steering gear stub shaft bearing kit, P/N 26032824, for service on the above-mentioned vehicles. For detailed usage, refer to Group Number 06 (Front Suspension-Steering) of the GM Parts Catalog. Previously, to correct a pinion seal leak or squeak, the steering gear assembly had to be replaced because the pinion stub shaft bearing, seal and seal retainer were not serviceable. Technicians may now order the kit instead of replacing the steering gear assembly. Disclaimer OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 4600 Fuel Injector Balance Test Example (Typical) Page 14022 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 170 For vehicles repaired under warranty use, the table. Disclaimer Locations Oxygen Sensor: Locations Engine, Right Side Page 1076 Steering Column Page 8624 For vehicles repaired under warranty, use the table. Disclaimer A/C - Broken Rear Window Defogger Grid Detection Rear Defogger: Technical Service Bulletins A/C - Broken Rear Window Defogger Grid Detection Bulletin No.: 04-08-48-001B Date: June 28, 2005 INFORMATION Subject: Rear Window Defogger - Broken Heating Grid Detection Method Models: 2006 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add the 2006 model year and additional models. Please discard Corporate Bulletin Number 04-08-48-001A (Section 08 - Body and Accessories). The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. Some new design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. If the vehicle does not have the vertical lines, the old (line-by-line) test methods can be used. Materials Required ^ Permatex(R) Quick Grid, GM P/N 12346001, or equivalent ^ A small ball of fine steel wool Type 00, or ^ Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or ^ Optional-A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: ^ the driver's side outboard of the two vertical lines ^ the passenger side outboard of the two vertical lines ^ the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following steps: Caution: ^ Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. ^ Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as an alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 3.1. Method using liquid crystal heat sensitive paper: Specifications Piston Ring: Specifications Piston Ring Top Groove to Ring Side Clearance 0 0017-0.0037 inch Second Groove to Ring Side Clearance 0.0017-0.0037 inch Oil Control Groove to Ring Side Clearance 0.0023-0.0085 inch Top Ring Gap - (3.66 inch) down from top of cylinder 0 0079-0.0157 inch Second Ring Gap - (3.66 inch) down from top of cylinder 0.0118-0.0197 inch Oil Control Ring Gap- (3.66 inch) down from top of cylinder 0.0098-0.0299 inch Page 2078 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Page 9199 Registered And Non-Registered Trademarks Part 6 Page 8807 Ambient Temperature Sensor / Switch HVAC: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2 wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and low reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0-5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the following conditions: The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 11831 Abbreviations And Meanings Part 16 Page 2239 Fuse Block - Underhood C2 Part 6 Fuse Block - Underhood C3 Part 1 Locations Cruise Control Switch (Multifunction Switch) Page 6193 Conversion - English/Metric Part 2 Page 5591 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 3469 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 3519 Body Control Module (BCM) C1 Part 1 Page 11893 Power Door Lock Actuator: Removal and Replacement Lock Actuator Replacement - Front Door Lock Actuator Replacement - Front Door Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the door latch assembly. 4. Remove the 2 screws that retain the actuator (1) to the lock. 5. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. 6. Remove the actuator from the latch. Installation Procedure 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. Important: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 3. Install the actuator to the top of the latch. Page 6899 Abbreviations And Meanings Part 14 Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 6802 Abbreviations And Meanings Part 6 Page 13971 Steps 4-6 The number(s) below refer to the step number(s) on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The Symptom Table will determine the correct diagnostic procedure to use. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Page 7817 4. Install the outer tie rod to the steering knuckle. Notice: to Fastener Notice on page P-9 in Cautions and Notices. 5. Install the outer tie rod retaining nut. Tighten the outer tie rod retaining nut to 60 Nm (44 ft. lbs.). 6. Install the tire and wheel. 7. Lower the vehicle. 8. Adjust the front toe. Page 2810 Abbreviations And Meanings Part 8 Page 13952 Abbreviations And Meanings Part 22 Page 2978 9. Remove the camshafts. 10. Using a suitable adapter, apply air pressure to the cylinder. 11. Install the J 44228 and compress the valve 12. Remove the valve keys. 13. Remove the J 44228. Page 9181 Abbreviations And Meanings Part 14 Service and Repair Trunk / Liftgate Stop: Service and Repair Bumper Replacement - Lift Gate Removal Procedure 1. Open the liftgate. 2. Remove the bolts that retain the bumper assembly to the body. 3. Remove the bumper assembly from the body. Installation Procedure 1. Position the bumper assembly to the body. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the bumper assembly to the body. Tighten the bolts to 25 N.m (18 lb ft). 3. Close the liftgate. Page 5169 6. Remove the 1-2 and 2-3 Shift solenoid retainers. 7. Remove the 1-2 and 2-3 Shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 5668 Park/Neutral Position Switch (C2) Page 552 Page 12566 Seat Heater: Connector Views Heated Seat Element - Driver Cushion Page 782 Page 1913 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 5622 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Page 10658 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 10021 Diagram Information and Instructions Rear Defogger: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 3450 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 3959 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data from the driver door module (DDM), Passenger door module (PDM) and the liftgate module (LGM) and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Page 409 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 9801 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 5122 Pressure Control (PC) Solenoid Valve Connector, Wiring Harness Side A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: Customer Interest A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Page 4062 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the fuel tank pressure harness connector. 3. Remove the fuel tank pressure sensor. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor seal. 2. Install the fuel tank pressure sensor. 3. Connect the fuel tank sensor harness connector. 4. Lower the vehicle. Page 10529 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 6256 1. Lubricate the new piston seals (3), the caliper bores, and the pistons (2) using clean brake fluid. 2. Install the piston seals (3). Ensure that the piston seals are not twisted in the caliper bore grooves. 3. Install the boot seals (1) on the pistons (2). 4. install the pistons in the caliper bores. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the bleeder valve (5) in the caliper housing (6). ^ Tighten the bleeder valve to 7 Nm (62 inch lbs.). 6. Install the bleeder valve cap (4). 7. Install the boot seals into the caliper housing bores using the J 8092 and the J 43885. Rear Brake Caliper Overhaul - Rear Disassembly Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions Page 3028 Timing Cover: Specifications Engine Front Cover Bolt 89 inch lbs. Engine Front Cover Spacer Bolt 89 inch lbs. Page 1016 29. Install the auxiliary heater pump and bracket onto the dash panel studs. 30. Reinstall the HVAC plate and nuts. 31. On the coolant bypass valve, remove the hose (1) that went from the valve to the engine and discard. Description and Operation Compact Disc Features Page 8221 Air Temperature Actuator - Right Page 3190 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Page 9193 Abbreviations And Meanings Part 26 Page 13768 Parts are currently available from GMSPO. Disclaimer Page 12902 Conversion - English/Metric Part 1 Page 10721 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Electrical - Intermittent Interior Electrical Concerns Control Assembly: All Technical Service Bulletins Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 10553 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 10276 Speaker - LR Door Page 8648 Hose/Line HVAC: Service and Repair Evaporator Tube Air Conditioning Evaporator Tube Replacement Tools Required - J 26549-E Orifice Tube Remover - J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. 2. Loosen the evaporator tube (5) from the evaporator. 3. Loosen the auxiliary evaporator tube (7) from the auxiliary piping. 4. Remove the evaporator tube nut from the condenser. 5. Remove the nuts (1, 2) retaining the evaporator tube to the fender. 6. Remove the washer solvent container. 7. Remove the coolant recovery tank. 8. Remove the evaporator tube using J 26549-E. 9. Remove the O-ring seal and discard. Installation Procedure 1. Install the new O-ring seal. Locations Washer Fluid Level Switch: Locations Forward Lamp Harness, Right Side Page 6999 Application Table Part 4 Location View Page 13071 Miniwedge (Door Jamb Switch) - RR Page 12964 Page 11718 1. Install the auxiliary power outlet to the trim panel. 2. Position the trim panel to the vehicle. 3. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 4. Index the locating tabs on the trim panel to the holes in the body. 5. Connect the wiring harness connector to the auxiliary power outlet. 6. Install the five screws that the retain the rear quarter trim panel to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear quarter trim panel screws to 2.5 N.m (22 lb in). 7. Install the seat belt lower anchor. Tighten Tighten the seat belt anchor bolt to 70 N.m (52 lb ft). 8. Install the left rear door sill panel. 9. Install the liftgate sill plate. 10. Install the left body side window forward garnish molding. 11. Install the left body side window rear garnish molding. 12. Return the third row seats to the upright position. 13. Install the cargo shelf. Trim Panel Replacement - Rear Quarter - Right - 1 TRIM PANEL REPLACEMENT - REAR QUARTER - RIGHT (TRAILBLAZER, ENVOY, BRAVADA) REMOVAL PROCEDURE Page 12406 Seat Adjuster Switch - Passenger (w/Heat) Part 2 Page 13551 Involved are certain 2004 Buick Rainier, 2003-2004 Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts Pre-ship Information - For US Only Important: An initial supply of flashers required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of July 18, 2005, and will be approximately 10% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Page 3301 Heater Hose: Service and Repair Heater Hose - Outlet With RPO Code LL8 HEATER HOSE REPLACEMENT - OUTLET (LL8) See: Application and ID/RPO Codes TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 2. Remove the transmission. 3. Remove the generator. 4. Using the J 43181 disconnect the outlet hose from the heater core outlet tube (1). 4.1. Install the J 43181 to the outlet heater core hose. 4.2. Close the tool around the outlet heater core hose. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the heater outlet hose (3) from the heater core (1). 6. Position the outlet heater hose clamp (6) at the water pump using J 38185. Page 11172 Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown this bulletin). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Page 10995 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 2904 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 27 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 9051 Seat Belt Buckle: Service and Repair Buckle Replacement - No. 2 Rear REMOVAL PROCEDURE 1. Remove the seat assembly from the vehicle. 2. Remove the grommet (1). Discard the old grommet. 3. Remove the seat belt buckle assembly from the seat. INSTALLATION PROCEDURE 1. Install the seat belt buckle assembly onto the seat. Page 2653 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Drive Belt Chirping Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive Page 10147 Page 1692 Page 3299 block. 3. Position the inlet heater hose clamp (1) at the engine block using J 38185. 4. Install the quick connect end of the outlet heater core hose (2) to the heater core. 5. Fill the engine cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. Body VIN 6 / GMT 370 HEATER HOSE REPLACEMENT - INLET (BODY TYPE VIN 6) TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6) in Cooling System. 2. Remove the coolant recovery reservoir. 3. Using the J 43181 disconnect the inlet heater hose (2) from the heater core inlet tube. 3.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 3.2. Close the tool around the inlet heater core hose. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 4. Reposition the hose clamp at the engine outlet using J 38185. 5. Remove the heater inlet hose (4) from the the engine block. 6. Remove the nut retaining the coolant bypass valve to the cowl. 7. Remove the heater inlet hose. INSTALLATION PROCEDURE A/T - Shift Lock Control Actuator Available Shift Interlock Solenoid: Technical Service Bulletins A/T - Shift Lock Control Actuator Available Bulletin No.: 05-07-129-001B Date: February 16, 2007 INFORMATION Subject: Automatic Transmission Shift Lock Control Actuator Available for Service Use Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2006 Chevrolet TrailBlazer EXT 2003-2006 Chevrolet SSR 2002-2007 GMC Envoy 2002-2006 GMC Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add the SSR. Please discard Corporate Bulletin Number 05-07-129-001A (Section 07 - Transmission/Transaxle). The automatic transmission shift lock control actuator is now available for service as a separate part. The actuator was formerly available only as part of the entire shifter assembly. DO NOT replace the shifter assembly if the shift lock control actuator requires replacement. Please refer to the Automatic Transmission Shift Lock Control Actuator Replacement procedure in the Automatic Transmission sub-section of the Service Information. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 4040 Powertrain Control Module (PCM) C2 Part 2 Page 10558 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 9143 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 13049 6. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 7. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Zone 6 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the RF door trim panel. Page 7736 Steering Gear: Service and Repair Rack & Pinion Gear Rack Bearing Preload Adjustment Rack and Pinion Gear Rack Bearing Preload Adjustment - Off Vehicle (Rack and Pinion) 1. Loosen the adjuster plug lock nut (1). 2. Turn the adjuster plug clockwise until the adjuster plug bottoms in the gear assembly. 3. Turn the adjuster plug back 50 degrees to 70 degrees (approximately one flat). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the adjuster plug lock nut (1) to the adjuster plug. Hold the adjuster plug stationary while tightening the adjuster plug lock nut (1) to 68 Nm (50 ft. lbs.). Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 13565 service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers, possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in Page 10504 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 1125 Seat Adjuster Switch Driver (w/o Memory) Part 2 Page 12236 Memory Seat Module - Passenger C4 Part 1 Page 10871 Abbreviations And Meanings Part 7 Page 12051 WA387E/57 - WA408G/44 Page 6816 Abbreviations And Meanings Part 20 Page 7079 C101 Part 2 Page 6914 Registered And Non-Registered Trademarks Part 3 Page 4088 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 12455 1. Install the small loop (1) onto the rear seat cushion latch (2). 2. Install the strap through the opening in the seat pan. 3. Install the rear-seat cushion cover and the pad. 4. Install the rear seat cushion assembly to the vehicle. Seat Cushion Cover and Pad Replacement - Rear No. 1 - 1 SEAT CUSHION COVER AND PAD REPLACEMENT - REAR NO. 1 (TRAILBLAZER, ENVOY, BRAVADA) TOOLS REQUIRED J 36796Clip Removal Tool REMOVAL PROCEDURE 1. Remove the seat cushion from the vehicle. 2. Remove the seat cushion bracket. Page 11152 Involved are certain 2002-2003 Chevrolet TrailBlazer EXT and GMC Envoy XL vehicles operated in corrosion areas and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts Pre-Ship Information Important: Page 8326 47. Connect the electrical connector to the A/C low pressure switch. 48. Install the lower air cleaner housing/washer solvent tank assembly onto the mounting studs. 49. Install the two air cleaner housing/washer tank assembly retaining nuts to the mounting studs. 50. Connect the washer pump hoses. 51. Connect the washer solvent tank electrical and install wiring harness to the retaining clips. 52. Install the air inlet duct to the lower air cleaner housing/washer solvent tank assembly. 53. Install the air cleaner filter element and air outlet duct. 54. Install the air cleaner cover. 55. Install the tender rear upper brace. 56. Connect the negative battery cable. 57. Recharge the refrigerant system. 58. Fill the cooling system. 59. Inspect the cooling system for leaks. 60. Leak test the refrigerant fittings using J 39400-A. Parts Information Warranty Information Page 2870 Intake Manifold: Service and Repair Intake Manifold Replacement Removal Procedure 1. Remove the throttle body. 2. Remove the PCM. 3. Disconnect all harnesses from the engine harness bracket. 4. Remove the front differential vent hose from the bracket clip. 5. Remove the engine harness bracket bolt and remove the bracket. 6. Disconnect the MAP sensor electrical connector. 7. Disconnect the crankcase ventilation hose. 8. Disconnect the brake hose at the booster. Page 5168 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Page 8407 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 6401 ^ If the brake pipe does NOT have the tooling mark (2), proceed to the next step of the inspection. 6. Clean and remove any dirt from the left front brake pipe and flare nut (3) where it connects to the ABS modulator under the vehicle. The left front pipe is on the top row and closest to the center of the vehicle. 7. Carefully inspect the brake pipe where the pipe goes into the flare nut for the same type of tooling mark (1) as shown above. The mark may be located at any point around the circumference of the pipe and a mirror flashlight may be required to see it. There will NOT be any of the spiral lines or grooves (2) in the tooling mark. ^ If the tooling mark IS present, then the brake pipe does NOT need to be replaced. Lower the vehicle and install the GM Recall Identification Label. ^ If the tooling mark is NOT present, then the brake pipe must be replaced. Proceed to the Replacement procedure, below. Replacement Procedure This replacement procedure should only be performed if the results of the Inspection procedure indicated that the brake pipe needed to be replaced. Bleeding of the hydraulic system is done using a pressure bleeder and is limited to the left front brake. This pressure bleeding procedure is a shortened version of the full vehicle procedure found in the Service Manual. As a result, the labor time included in this recall for bleeding the brake system is less. Important To avoid unnecessary brake fluid loss, have the new brake pipe ready to install before you begin removing the old pipe. 1. Disconnect the brake pipe (1) from the left front caliper brake hose fitting. 2. From underneath the vehicle, disconnect the other end of the brake pipe (1) from the ABS modulator located on the inboard side of the left frame rail. 3. Disconnect the pipe from the lower retainers on the frame. 4. Disconnect the pipe from the upper retainer on the frame. Page 2820 Abbreviations And Meanings Part 18 Page 10833 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 5175 Torque Converter Clutch Solenoid: Diagrams Torque Converter Clutch Pulse Width Modulated (TGC PWM) Solenoid Valve Connector, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side Page 6009 For vehicles repaired under warranty, use the table. Disclaimer Page 4468 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 10124 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 9432 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 13022 Abbreviations And Meanings Part 23 Page 9816 Abbreviations And Meanings Part 8 Page 7629 Ride Height Sensor: Service and Repair Air Spring Leveling Sensor Replacement Removal Procedure Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensor to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Ensure that the vehicle is parked on level surface. 3. Inspect tires for proper tire pressure. 4. Inspect the air suspension system components for damage or defects. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the rear tire and wheels. 7. Support the rear axle and set the rear axle to proper D height. 8. Disconnect the air spring level sensor link from the upper control arm. 9. Disconnect the air spring level sensor electrical connector. Page 1007 40.6. Install the ring terminal (orange wire) to the underhood fuse block stud (1). 40.7. Locate circuit no. 241 or 441 (ignition 3 brown wire) (PIN B11 or C11) in the existing underhood fuse block harness (1) of C2 (2) and splice bare wire to it using a splice clip. Wrap with electrical tape. 40.8. Locate connector C105 (3), located on the left side inner fender. Separate the connector halves. On the female side of the connector, remove the terminal from cavity F (gray/black wire) and tape back. 40.9. Install the terminal end on the pump wiring harness into cavity F of connector C105. 41. Install the evaporator tube and nut to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 42. Install the coolant recovery reservoir with the accumulator attached. 43. Install the nut and bolt securing the coolant recovery reservoir. 44. Install the coolant hoses to the coolant recovery reservoir. 45. Install the nut retaining the accumulator to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 46. Install the compressor suction hose assembly to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). Engine Controls - Above Normal Temp. Gauge Readings PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4301 Body Control Module (BCM) C1 Part 2 Page 11296 bulkhead. 3. Install the cable to the release handle (3). 4. Seat the cable grommet (1) to the bulkhead. 5. Install the release handle (3) to the left side cowl panel. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the nut (2) that retains the release handle (3) to the left side cowl panel. Tighten the nut to 7 N.m (62 lb in). 7. Route the cable as previously noted, over the battery tray, between the headlamp panel assembly and the radiator. 8. Attach the cable to the retainers on the wheelhouse and the hood hold open rod bracket. 9. Install the cable to the hood latch assembly. 10. Install the hood latch. 11. Install the front grille. 12. Install the left closeout/insulator panel. 13. Install the left front door sill panel. Page 4365 Powertrain Control Module (PCM) C3 Part 3 Heater Hose - Inlet Heater Hose: Service and Repair Heater Hose - Inlet Body VIN 3 / GMT 360 HEATER HOSE REPLACEMENT - INLET (BODY TYPE VIN 3) TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 2. Using the J 43181, disconnect the inlet heater hose (2) from the heater core inlet tube. 2.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 2.2. Close the tool around the inlet heater core hose. 2.3. Firmly pull the tool into the quick connect end of the heater hose. 2.4. Firmly grasp the heater hose (2). Pull the heater hose forward in order to disengage the hose from the heater core. 3. Position the inlet heater hose clamp (1) at the engine block using J 38185. 4. Remove the heater inlet hose (2) from the inlet hose fitting at the engine block. 5. Remove the heater inlet hose. INSTALLATION PROCEDURE 1. Apply coolant to the end of the heater inlet hose. 2. Install the heater inlet hose (2) to the inlet hose fitting at the engine block. IMPORTANT:When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine Page 10657 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 1996 1. Install the air cleaner element (1) onto the air outlet duct (2) with a twisting and pushing motion. 2. Snap the air cleaner element (1) and air outlet duct (3) into the lower air cleaner housing/washer solvent tank assembly (2). 3. Install the air cleaner cover/resonator assembly (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the three air cleaner cover/resonator retaining screws (2) one shown, to 4 N.m (35 lb in). 4. Install the radiator air intake baffle if applicable. 5. Install the radiator support diagonal brace if applicable. Page 11701 1. Remove the bolt that retains the seat belt upper anchor to the body. 2. Remove the garnish molding from the vehicle. INSTALLATION PROCEDURE 1. Install the garnish molding to the vehicle. 2. Install the seat belt retractor to the body. 3. Install the bolt that retains the seat belt anchor to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the anchor bolt to 70 N.m (52 lb ft). Garnish Molding Replacement - Center Pillar GARNISH MOLDING REPLACEMENT - CENTER PILLAR REMOVAL PROCEDURE Page 2251 Application Table Part 2 Page 2805 Abbreviations And Meanings Part 3 Page 13227 Specifications Power Steering Fluid: Specifications Fluid Type .......................... GM Power Steering Fluid GM P/N 1052884 - 1 pint (Canadian P/N 993294), 1050017 - 1 quart, (Canadian P/N 992646) or equivalent. Page 4933 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4231 Page 10844 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 9868 Global Positioning System Antenna: Service and Repair Navigation Antenna Replacement NAVIGATION ANTENNA REPLACEMENT REMOVAL PROCEDURE 1. Ensure the ignition is in the OFF position. 2. Remove the electrical connector from the antenna. 3. While maintaining a parallel angle to the windshield, remove the antenna from the bracket by sliding the antenna away from the headliner. INSTALLATION PROCEDURE 1. Position the antenna to the bracket. 2. While maintaining a parallel angle to the windshield, install the antenna to the bracket by sliding the antenna towards the headliner. Ensure the antenna is fully seated to the bracket. 3. Install the electrical connector to the antenna. Service Precautions Hose/Line HVAC: Service Precautions CAUTION: DO NOT REMOVE HOSES OR LINES BEFORE SYSTEM IS FULLY DISCHARGED. MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED. Page 1963 component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Page 10884 Abbreviations And Meanings Part 20 Page 193 Page 13013 Abbreviations And Meanings Part 14 Page 8427 Blower Motor Switch: Diagrams Blower Motor Switch - Front Auxiliary (Body Type VIN 6) Page 7912 8. Remove the air spring from the vehicle. Installation Procedure 1. Install the air supply line to the air spring. Ensure the air supply line is fully seated. Caution: Ensure that the air spring is fully seated and properly positioned on the axle pilot. Failure to properly position the air spring may cause the air spring to break apart, possibly resulting in personal injury or damage to the vehicle. 2. Install the air spring (2) to the frame by aligning the mounting tabs (3) with the keyhole slots (1) in the upper spring seat. 3. Apply upward pressure to the air spring (2) and rotate clockwise until the antirotation peg snaps into place. 4. Pressurize the air suspension system. 5. Lower the vehicle. 6. Install the air suspension system fuse. 7. Start the vehicle and run for approximately 1 minute to ensure that the air suspension system is functioning properly. 8. Inspect the D height. Page 6569 Page 12843 Abbreviations And Meanings Part 20 Page 3955 Body Control Module (BCM) C3 Part 4 Page 2185 6. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 7. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 8. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 9. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. 10. Install the SIR fuse to the fuse block (1) located in the underhood electrical center. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition. Page 6661 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 2921 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 5189 8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. 9. Inspect the 1-2 accumulator piston for the following defects: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 10. Inspect the 1-2 accumulator cover for the following defects: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 11. Remove the spacer plate support retaining bolts. Important: Use care not to drop the following items that will be removed along with the spacer plate: ^ The number 1 checkball Page 12910 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 3340 Radiator: Description and Operation Radiator The radiator is a heat exchanger, consisting of a core and 2 tanks. The aluminum core is a tube and fin crossflow design that extends from the inlet tank to the outlet tank. Fins are placed around the outside of the tubes to improve heat transfer to the atmosphere. The inlet and outlet tanks are a molded, high temperature, nylon reinforced plastic material. A high temperature rubber gasket seals the tank flange edge to the aluminum core. The tanks are clamped to the core with clinch tabs. The tabs are part of the aluminum header at each end of the core. The radiator also has a drain cock located in the bottom of the left hand tank. The drain cock unit includes the drain cock and drain cock seal. The radiator removes heat from the coolant passing through the core. The fins on the core transfer heat from the coolant passing through the tubes. As air passes between the fins, the air removes the heat and cools the coolant. Page 4075 Page 5878 8. Lower the Vehicle. Page 7387 6. Connect the mobile telephone harness connector (1) to the junction block. 7. Connect the instrument panel harness connector (1) to the block base. 8. Install the junction block to the block base. Ensure that the retaining tabs are fully seated. Page 7468 Multiple Junction Connector: Diagrams C201 - C203 C201 Part 1 Page 1233 Ambient Temperature Sensor / Switch HVAC: Service and Repair Intake Air Temperature Sensor Lower Left AIR TEMPERATURE SENSOR REPLACEMENT - LOWER LEFT REMOVAL PROCEDURE 1. Remove the IP assembly. 2. Disconnect the electrical connector from the air temperature sensor-lower left (2). 3. Remove the air temperature sensor-lower left. INSTALLATION PROCEDURE 1. Install the air temperature sensor-lower left (2). 2. Connect the electrical connector to the air temperature sensor-lower left. 3. Install the IP assembly. Lower Right AIR TEMPERATURE SENSOR REPLACEMENT - LOWER RIGHT REMOVAL PROCEDURE 1. Remove the passenger side closeout panel. 2. Remove the IP lower closeout panel. Page 7003 7. Remove the junction block bracket retaining bolts (1) and remove the junction block bracket from the vehicle. INSTALLATION PROCEDURE 1. Position the junction block bracket and install the bolts (1). Tighten Tighten the junction block bracket bolts to 6 N.m (53 lb in). 2. Align the wiring harnesses and install the fuse relay center. 3. Install the fuse relay center bolts (3). Tighten Tighten the relay center bolts to 6 N.m (53 lb in). Page 10201 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 2544 10. Remove fixture EN 45680-401, cylinder bore sleeve puller EN 45680-402, and the cylinder bore sleeve (117) from the engine block. 11. Loosen the nut (1) in order to remove the cylinder bore sleeve (117). 12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block. 13. Inspect the piston, piston rings, and connecting rod for damage. Refer to Piston, Connecting Rod, and Bearings Cleaning and Inspection. Cylinder Bore Sleeve Installation Note: Do not use assembly aids or lubricants on the cylinder bore sleeve or the cylinder bore block when installing a new cylinder bore sleeve, or engine damage will occur. These items will not aid in the installation of the new cylinder bore sleeve. Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. 1. Place the NEW cylinder bore sleeve (117), P/N 88984239, onto the cylinder block. Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 3371 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. 2. Disconnect the negative battery terminal. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the Locations Electronic Components Page 8724 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. See: Specifications/Capacity Specifications Page 75 Abbreviations And Meanings Part 20 Locations Upper Console Page 5653 15. A hidden yellow identification band indicates proper joint seating. 16. Inspect the transmission fluid level. Page 10822 Page 1880 Disclaimer Page 12201 Door Module: Electrical Diagrams Door Control Module Diagram 1 Page 3957 Door Control Module Diagram 2 Page 12636 2. Install the seat switches to the switch bezel, verifying that the retaining tabs are fully seated. 3. Install the switch bezel to the seat with the 3 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the front seat switch bezel screws to 3 N.m (26 lb in). Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the switch bezel assembly from the seat assembly. 2. Remove the buttons from the switch. 3. Release the tabs that retain the seat switch to the seat bezel assembly. 4. Disconnect the electrical connector from the switch. 5. Remove the seat switch from the seat bezel assembly. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. Page 5651 5. Ensure that the three retaining ring ears are seen from inside the fining and that the retaining ring moves freely in the fining slots. 6. Install the new retaining ring (E-clip) into the remaining quick connect fittings. 7. Install the cooler lines into the quick connect fining. 8. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 9. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 10. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fining. Connector Views Vanity Lamp: Connector Views Vanity Mirror Lamp - LF Page 7301 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram Page 2237 Fuse Block - Underhood C2 Part 4 Page 12819 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 10624 Page 2691 Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement Removal Procedure 1. Remove the drive belt. 2. Remove the idler pulley bolt from the idler pulley bracket. 3. Remove idler pulley. Installation Procedure NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the idler pulley and secure the pulley with the bolt. Tighten the idler pulley bolt to 50 Nm (37 ft. lbs.). 2. Install the drive belt. Page 9348 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 8852 approximately 25 mm (1 in) away from the connector so the wires can be fed into the slot. Feed the wires into the slot and install the harness to the plastic guide. Connect the harness electrical connector to the cooling fan clutch. Install the cooling fan. Refer to the Cooling Fan and Shroud Replacement procedure in the Engine Cooling sub-section of SI. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 9929 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 10316 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 8933 9. Verify that the tabs on the lower shroud (1) engage with the tabs on the upper shroud (2). Snap the tabs together. Tighten Tighten the screws to 1.5 N.m (13 lb in). 10. On vehicles with a tilt column, align the tilt lever into the steering column. 11. Slide the tilt lever handle into the steering column until the handle locks into position. 12. Feed the wiring through the steering wheel. 13. Align the steering wheel with the mark on the steering shaft. Install the steering wheel onto the shaft. 14. Install the nut for the steering wheel. Tighten Tighten the nut to 41 N.m (30 lb ft). 15. Install the inflatable restraint steering wheel module. 16. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3. Page 2219 Fuse Block - Rear C2 Part 4 Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 12071 WA8555/41 - WA8555/41 Page 3889 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 12496 Page 10062 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 710 Chassis Harness, Frame-Left Side Page 11765 Front Passenger Door Module (FPDM) Page 6754 Page 13979 Steps 6-12 Page 3400 1. Install a new water pump gasket. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the water pump and secure the water pump with the bolts. Tighten ^ On the initial pass, tighten the bolts to 4 Nm (35 lb in). ^ On the final pass, tighten the bolts to 10 Nm (89 lb in). 3. Install the water pump pulley. 4. Install the water pump pulley bolts. 5. Using the J 41240, secure the water pump pulley while tightening the water pump pulley bolts. Tighten Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41240. 7. Install the drive belt. 8. Install the fan and the shroud. 9. Fill the cooling system with the specified coolant and concentration. 10. Inspect for leaks. Fuse Block - Rear (Long Wheelbase) Fuse Block: Application and ID Fuse Block - Rear (Long Wheelbase) Location View Page 12331 1. Install the cover to the head restraint. 2. Install the J-strips on the bottom of the head restraint cover. 3. Install the front seat head restraint. Head Restraint Replacement - Rear Seat Head Restraint Replacement - Rear Seat Removal Procedure 1. Raise the head restraint to the full up position. 2. Adjust the seat cushion just below the top of the seat back in order to gain access to the retaining clip on each head restraint post. 3. Remove the retaining clip from each head restraint post. 4. Remove the head restraint from the seat back. Installation Procedure 1. Install the retaining clips to the head restraint retractor. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Locations Power Seat Motor: Locations Front Passenger Seat Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 318 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 6202 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 9924 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Specifications Connecting Rod: Specifications Connecting Rod Cap Bolt First Pass 18 ft. lbs. Final Pass 110 degrees Connecting Rod Connecting Rod Bearing Journal Diameter 2.2337-2.2342 inch Connecting Rod Bearing Journal Out Of Round - Maximum 0.0002 inch Connecting Rod Bearing Bore Diameter 2.3749-2.3755 inch Connecting Rod Inside Bearing Diameter 2.2351-2.2362 inch Connecting Rod Bearing Journal Clearance 0.0008-0.0025 inch Connecting Rod Side Clearance 0.0019-0.0137 inch Connecting Rod Bushing to Pin Clearance 0.0004-0.0007 inch Connecting Rod Inside Bushing Diameter 0.9055-0.9060 inch Page 6296 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Page 10066 Labor Time Information Page 3604 Camshaft Position (CMP) Sensor Page 8422 Blower Motor Resistor: Service and Repair Auxiliary Replacement BLOWER MOTOR RESISTOR REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the rear HVAC module assembly. 2. Disconnect the electrical connector from the blower motor control processor-auxiliary (3). 3. Remove the screws from the blower motor control processor-auxiliary (3). 4. Remove the blower motor control processor-auxiliary (3). 5. Remove the thermal gasket from the evaporator core-auxiliary surface. INSTALLATION PROCEDURE 1. Install the thermal gasket to the blower motor control processor-auxiliary. 2. Install the blower motor control processor-auxiliary (3). 3. Install the screws to the blower motor control processor-auxiliary (3). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to .....2 N.m (18 lb in). 4. Connect the electrical connector to the blower motor control processor-auxiliary (3). 5. Install the HVAC module-auxiliary. Page 11004 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 3147 Water Pump: Service and Repair Water Pump Replacement (4.2L Engine) Tool Required J 41240 Fan Clutch Wrench Removal Procedure 1. Drain the coolant. 2. Remove the fan and shroud. 3. Remove the drive belt. 4. Using the J 41240, secure the water pump pulley and remove the water pump pulley bolts. 5. Remove the J 41240. 6. Remove the water pump pulley. 7. Loosen and remove the water pump bolts. 8. Remove the water pump. 9. Clean and inspect the water pump. 10. Discard and replace the gasket. Installation Procedure Page 5305 For vehicles repaired under warranty, use the table. Important: ^ This labor time ONLY applies to vehicles repaired WITHOUT the transmission removed from the vehicle. ^ NO additional labor time is required for installation of the fill tube while the transmission is removed from the vehicle for repair. Disclaimer Page 12323 1. Install the cover to the head restraint. 2. Install the J-strips on the bottom of the head restraint cover. 3. Install the front seat head restraint. Head Restraint Replacement - Rear Seat HEAD RESTRAINT REPLACEMENT - REAR SEAT REMOVAL PROCEDURE 1. Raise the head restraint to the full up position. 2. Adjust the seat cushion just below the top of the seat back in order to gain access to the retaining clip on each head restraint post. Page 10311 Page 8853 Disclaimer Page 6223 Abbreviations And Meanings Part 22 Page 4133 Abbreviations And Meanings Part 19 Page 6301 6. Compress the front brake caliper piston. 6.1. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. 6.2. Slowly tighten the C-clamp until the piston pushes into the brake caliper enough to slide the brake caliper off the rotor. 6.3. Remove the C-clamp from the brake caliper. 7. Remove the mounting bolts from the brake caliper mounting bracket. Important: When performing the following service procedure, the front brake caliper assembly and the front brake caliper mounting bracket can be removed as an assembly. 8. Remove the brake caliper and mounting bracket assembly. Page 3799 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Locations Impact Sensor: Locations Locations View Page 12509 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 474 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 8182 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 3834 Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... ................................................ 18.0 Nm (13.0 lb. ft.) Spark Plug Gap ................................................ ..................................................................................................................................... 1.08 mm (0.0425 in.) Page 7501 C600 Part 1 Service and Repair Turn Signal Bulb: Service and Repair PARK/TURN SIGNAL/SIDE MARKER LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Rotate the bulb and socket counterclockwise in order to remove the bulb and socket from the housing. 3. Remove the side marker bulb (4) or turn signal/park bulb (3) from the socket. INSTALLATION PROCEDURE 1. Install the side marker bulb (4) or turn signal/park bulb (3) to the socket. 2. Wipe the bulb with a clean cloth to ensure the bulb is free of any dirt or oil. 3. Install the bulb and socket to the headlamp by rotating the bulb and socket clockwise, locking the retaining tabs to the headlamp. 4. Close the hood. Locations Electronic Components Page 3840 2. Install the spark plugs to the engine. Tighten the spark plugs to 18 Nm (13 lb ft). 3. Install the ignition coils. Refer to Ignition Coil Replacement. Page 440 Page 2758 Page 7514 Application Table Part 4 Location View Page 8361 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 9763 Page 1757 Abbreviations And Meanings Part 21 Page 11002 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 1184 Page 969 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 6773 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 11407 3. Remove the C clip from the groove in the lock cylinder. 4. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the C clip to the groove in the lock cylinder. 3. Install the lock rod to the lock cylinder. 4. Install the rear wiper motor. Refer to Wiper Motor Replacement - Rear. Page 11031 5. Center punch each weld location. IMPORTANT: Drill through the hinge base only (1). Do not drill through the mating surface (2). 6. At each punch location, drill a 3 mm (1/8 in.) pilot hole (1). 7. Using the pilot hole as a guide, drill through the hinge base using a 19 mm (3/4 in.) rotabroach hole saw or equivalent (2). IMPORTANT: If necessary, use a chisel to separate the hinge from the mating surface. 8. Remove the hinge. Page 13056 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module yellow 4-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 1. Remove the key from the ignition. Page 4261 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 9022 9. Remove the lower seat belt retractor retaining bolt and nut. 10. Remove the retractor assembly by pulling the push pin (2) from the seat back frame. 11. Remove the seat belt retractor bracket bolt (1) from the bracket and seat back frame. 12. Remove the seat belt retractor bracket from the seat back frame. INSTALLATION PROCEDURE Page 7105 C307 Part 2 Page 10686 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 12392 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Part 2 Page 8599 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to .....2 N.m (18 lb in). 5. Install the blower motor control processor-auxiliary. 6. Install the backing plate (1) to the evaporator core-auxiliary. 7. Install the evaporator block-auxiliary. 8. Install the inverted torx studs to the evaporator block-auxiliary. Tighten Tighten the torx studs to .....2 N.m (18 lb in). 9. Install the heater core-auxiliary. 10. Leak test the fittings of the component using the J 39400-A. Page 901 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data from the driver door module (DDM), Passenger door module (PDM) and the liftgate module (LGM) and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Page 6556 Part 2 of 2 Page 6636 Page 5889 Universal Joint: Service and Repair Universal Joint Replacement - External Snap Ring Universal Joint Replacement - External Snap Ring Tools Required ^ J9522-3 U-Joint Bearing Separator ^ J9522-5 U-Joint Bearing Spacer Remover Disassembly Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller shaft in order to show which end connects to the transmission and which end goes to the rear axle. 3. Disassemble the snap rings by pinching the ends together with a pair of pliers. 4. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 5. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 inch) hex head socket or a 27 mm (1-1/16 inch) socket. 6. Place J9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 7. If you do not completely remove the bearing cup, lift the cross and insert J9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 8. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 9. Mark the orientation of the slip yoke to the tube for proper reassembly. 10. Remove the cross from the yoke. 11. Remove the remaining universal joint parts from the yoke. 12. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 13. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 14. Inspect the bearing cup bores for burrs or imperfections. 15. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or Page 1383 Engine Coolant Temperature (ECT) Sensor Body - Center Mount Brake Lamp Applique loose Center Mounted Brake Lamp: All Technical Service Bulletins Body - Center Mount Brake Lamp Applique loose Bulletin No.: 01-08-66-007C Date: August 27, 2007 TECHNICAL Subject: Center High-Mount Stop Lamp (CHMSL) Applique Loose (Re-Tape Applique) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2008 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to include additional model years and change step 7 in the procedure. Please discard Corporate Bulletin Number 01-08-66-007B (Section 08 - Body and Accessories). Condition Some customers may comment that the CHMSL applique is loose on the liftgate glass. Cause A poor bonding of the double-sided adhesive tape between the CHMSL applique and the liftgate glass may cause this condition. Correction Re-tape the CHSML applique to the liftgate glass using the following service procedure: Open the liftgate glass. Remove the screws that retain the applique to the liftgate glass. Do not damage the applique or the liftgate glass when removing the applique from the liftgate glass. With a flat-bladed tool, carefully remove the applique from the liftgate glass. Remove the CHMSL harness grommet from the roof panel. Disconnect the CHMSL harness connector. Place a clean fender cover on a suitable working surface and place the applique on the fender cover. Remove the old adhesive from the underside of the applique. (For Saab Only Remove the two screws from the CHMSL and remove the CHMSL from the applique. Remove all the ribs from the back side of the applique as seen in illustration above. Clean the applique and the CHMSL with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984 or equivalent, and dry thoroughly using a clean low lint towel or towelette. Apply double-sided adhesive tape, 3M(R) P/N 06397 or equivalent to the CHMSL lens as seen in the illustration below and install the two screws and tighten). Tighten Page 10920 2. Connect the 24-way gray electrical connector (1) to the BCM. 3. Connect the 32-way tan electrical connector (2) to the BCM. 4. Connect the body wiring extension (1) to the BCM. 5. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. Page 138 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 6848 Description and Operation ABS Light: Description and Operation ABS Indicator The IPC illuminates the ABS indicator when the following occurs: ^ The Electronic Brake Control Module (EBCM) detects an ABS-disabling malfunction. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check. ^ The IPC detects a loss of class 2 communications with the EBCM. Page 1015 16. Remove the nut and bolt securing the coolant recovery reservoir. 17. Remove the coolant recovery reservoir with the accumulator attached. 18. Remove the evaporator tube nut at the evaporator. 19. Remove the evaporator tube from the evaporator 20. Using the J 43181, disconnect the heater hoses from the core. 20.1. Install the J 43181 to the heater core hose. 20.2. Close the tool around the heater core hose. 20.3. Firmly pull the tool into the quick connect end of the heater hose. 20.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 21. Disconnect the coolant bypass valve hose from the auxiliary rear heater line. 22. Disconnect the coolant bypass valve hose from the engine. 23. Disconnect the electrical connector from the coolant bypass valve. This connector will no longer be used. Tape off with electrical tape. 24. Disconnect the vacuum hose from the coolant bypass valve. 25. Remove the nut retaining the coolant bypass valve to the cowl and remove the coolant bypass valve with hoses attached. 26. Remove the heater hose quick connect retainers from the heater core pipes. 27. Remove the four nuts and the HVAC plate from the dash panel. 28. Attach the new auxiliary heater pump to the new bracket using the supplied retainers as shown. Note the position of the pump on the bracket. Page 2828 Abbreviations And Meanings Part 26 Page 10183 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Lighting - Tail Lamp(s) Inoperative Tail Light Bulb: Customer Interest Lighting - Tail Lamp(s) Inoperative Bulletin No.: 03-08-42-006B Date: May 26, 2004 INFORMATION Subject: Tail Lamp Circuit Board Now Available For Service Use Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add a part number. Please discard Corporate Bulletin Number 03-08-42-006A (Section 08 - Body and Accessories). A new tail lamp circuit board is now available for service use. If normal diagnosis of a vehicle leads to a failed tail lamp bulb, inspect the bulb socket to ensure proper fit of the bulb into the socket. If the bulb is found to be loose, or if the circuit board has failed, replace both tail lamp circuit boards with the new part number from GMSPO. Technicians are to replace the tail lamp circuit boards, on both sides of the vehicle, using the following procedure: 1. Remove the tail lamp assembly from the vehicle. 2. Remove the tail lamp circuit board from the tail lamp assembly. 3. Inspect for loose tail lamp bulbs in the tail lamp circuit board. Replace the tail lamp bulb and the tail lamp circuit board if necessary. 4. Install the tail lamp circuit board. 5. Install the tail lamp assembly. 6. Replace the tail lamp circuit board on the opposite side of the vehicle using the above procedure. 7. Verify the operation of the tail lamps. Parts Information Page 10659 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 4151 Splice Pack SP306 Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 10185 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 3324 Disclaimer Locations Electronic Components Page 8660 3. Install the HVAC module mounting bolts (5). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the bolts to .....10 N.m (89 lb in). 4. Install the air outlet ducts (5). 5. Connect the electrical connectors. 6. Install the right side rear quarter trim panel. 7. Raise and support the vehicle. Automatic Transmission Range Selector Cable Replacement Shift Cable: Service and Repair Automatic Transmission Range Selector Cable Replacement Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Ensure that the vehicle is in the park position. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the end of the range selector cable from the transmission range selector lever ball stud (6). 4. Remove the retainer (5) from the range selector cable. 5. Remove the range selector cable (4) from the bracket (1). 6. Remove the cable from the retainer (3) on the floor panel. If the vehicle is equipped with 4WD, remove the cable from the retainers located on the transfer case. 7. Push the cable grommet (2) up through the floor panel. 8. Lower the vehicle. Page 6696 Abbreviations And Meanings Part 18 Page 12928 Abbreviations And Meanings Part 17 Page 3934 Abbreviations And Meanings Part 21 Page 6271 9. Remove the outboard brake pad. 10. Remove the inboard brake pad. 11. Remove the brake pad retaining clips from the brake caliper mounting bracket. Description and Operation Cassette Features Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 3883 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 8273 4. Remove the outlet assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the outlet assembly to the IP. 2. Install the retaining screw. Tighten Tighten the screw to .....2.5 N.m (22 lb in). Page 12558 Abbreviations And Meanings Part 26 Page 3925 Abbreviations And Meanings Part 12 Page 1261 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Page 2235 Fuse Block - Underhood C2 Part 2 Page 12840 Abbreviations And Meanings Part 17 Page 5832 1. Install the ring gear to the differential case. 2. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the new ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten the ring gear bolts in sequence to 120 Nm (89 ft. lbs.). 4. Install the drive pinion bearing cups. 5. Determine the selective shim thickness for the pinion gear. 6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing onto the pinion. 8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. 10. Install the pinion to the axle housing. 11. Install the outer pinion bearing. 12. Install a new pinion oil seal using the J38694. 13. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. Page 6221 Abbreviations And Meanings Part 20 Page 448 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 252 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 10251 Amplifier: Diagrams Audio Amplifier C2 (With RPO Code UQA) Audio Amplifier C2 (With RPO Code UQA) Part 1 Page 6278 4. Rotate the rear brake caliper upward until the brake caliper assembly is in the proper position. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the upper brake caliper mounting bolt. ^ Tighten the brake caliper bolt to 31 Nm (23 ft. lbs.). 6. Install the tire and wheel assembly. 7. Lower the vehicle. Refer to Vehicle Lifting. 8. Fill the brake master cylinder reservoir (if needed). Caution: Refer to Firm Brake Pedal Caution in Service Precautions. 9. Pump the brake pedal slowly and firmly in order to seat the brake pads. 10. Burnish the new brake pads. Page 7317 Application Table Part 3 Location View Page 10388 Steps 1-6 Page 12896 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Description and Operation Temperature Warning Lamp/Indicator: Description and Operation Engine Coolant Indicator ENGINE COOLANT HOT IDLE ENGINE The radio activates an audible warning as requested by the Instrument Panel Cluster (IPC). The IPC sends a class 2 message to the radio indicating the chime duration of 4 pulses. The warning sounds and the appropriate indicator illuminates in the Driver Information Center (DIC) when the following occurs: - The IPC determines that the coolant temperature is greater than 125°C (257°F). The IPC receives a class 2 message from the PCM indicating coolant temperature. - The IPC performs the displays test at the start of each ignition cycle. The indicator illuminates for approximately 3 seconds. The IPC turns OFF the engine coolant indicator when the engine coolant falls below 122°C (252°F). Page 8281 Air Temperature Sensor-Lower Right Engine Controls - Underhood Ticking Noise Fan Clutch: All Technical Service Bulletins Engine Controls - Underhood Ticking Noise Bulletin No.: 05-06-02-004 Date: April 06, 2005 TECHNICAL Subject: Underhood Tick Noise at Idle (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada Condition Some customers may comment on an underhood tick noise heard while the vehicle is idling. Technicians may find that the noise does not increase or decrease with changes in the engine idle RPM. The tick noise occurs at approximately one second intervals. Cause This condition may be caused by the electro-viscous fan clutch control function of the Powertrain Control Module (PCM) attempting to keep the fan speed between 300-600 revolutions per minute (RPM). At idle, the cooling fan speed will drag to approximately 500 RPM then oscillate between 300 and 600 RPM. When the fan speed drops below 500 RPM, the PCM will pulse the fan control solenoid. The pulsing of the solenoid is the cause of the ticking noise. Correction Technicians are to verify that the cooling fan clutch is the source of the noise by using either one of the following two methods: ^ Use a Tech 2(R) to command the cooling fan off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. ^ The cooling fan clutch electrical connector, located on the cooling fan shroud, may be disconnected with the engine off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. Be sure to clear any Diagnostic Trouble Codes (DTCs) that may have set while the cooling fan clutch is disconnected. Technicians are to reprogram the PCM with an updated software calibration. The new software calibration is currently available in TIS for all the vehicles listed above. Warranty Information Page 13948 Abbreviations And Meanings Part 18 Page 9212 Steps 3-7 Body Side Hinge - A Pillar Front Door Hinge: Service and Repair Body Side Hinge - A Pillar Body Side Hinge - A Pillar REMOVAL PROCEDURE IMPORTANT: The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all hinges. 1. Remove all of the related panels and components. 2. Remove the sealer surrounding the hinge (1). 3. Scribe the location of the hinge (1). 4. Hand-sand the existing hinge (1) with 100 grit sandpaper to locate the four weld locations. IMPORTANT: Punch the center of the weld so that as much of the weld as possible is removed during drilling. Diagrams Transmission Range Switch Connector, Wiring Harness Side Page 7472 C201 Part 5 Page 1689 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 13010 Abbreviations And Meanings Part 11 Page 5677 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Page 8008 Vehicle Lifting: Service and Repair LIFTING AND JACKING THE VEHICLE CAUTION: - To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. - To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. NOTE: Perform the following steps before beginning any vehicle lifting or jacking procedure: - Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. - The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. - The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. - Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. - Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Page 9487 Page 8502 HVAC Control Module - Auxiliary (Body Type VIN 6) Part 2 HVAC System - Manual Page 10199 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 4699 Fuel Supply Line: Service and Repair Fuel Hoses/Pipes Replacement - Filter to Tank REMOVAL PROCEDURE CAUTION: Refer to Fuel and EVAP Pipe Caution in Service Precautions. - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. NOTE: Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Service Precautions. 1. Remove the fuel tank. 2. Disconnect the fuel feed pipe from the fuel sender assembly (4). 3. Disconnect the fuel feed pipe from the fuel filter (7). 4. Disconnect the fuel return pipe from the fuel sender assembly (4). 5. Disengage the fuel pipe clip (6) at the front of the fuel tank. 6. Remove the fuel pipes. INSTALLATION PROCEDURE 1. Connect the fuel return pipe to the fuel sender assembly (4). 2. Connect the fuel feed pipe to the fuel filter (7). 3. Connect the fuel feed pipe to the fuel sender assembly (4). 4. Install the fuel pipe clip (6) to the fuel pipes at the front of the fuel tank. 5. Install the fuel tank. Page 9162 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 10889 Abbreviations And Meanings Part 25 Page 2348 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 12650 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lift up on the front edge of the door lock and side window switch (1) in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. Remove the electrical connector (2) from the memory seat switch. 4. Remove the memory seat switch from the lock and door lock and side window switch (1). INSTALLATION PROCEDURE Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Page 8504 HVAC Control Module C1 Part 1 Page 9772 Page 3709 Crankshaft Position (CKP) Sensor Page 13260 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 6435 5. Release the wiring harness from the retaining clips (2) on the frame and reposition the harness as necessary to allow for removal of the brake pipe. 6. Disconnect the wheel speed sensor harness connector (1) located on the outboard side of the left frame rail near the front caliper brake hose fitting. 7. From the left front wheelhouse, remove the brake pipe from the vehicle. 8. Position the new brake pipe to the vehicle and install it in the retainers on the frame. Notice To avoid damaging the threads on the ABS modulator, flare nuts, or the front brake hose fitting, use only your fingers to start the threads. Do not use tools to start threading the flare nut into the ABS modulator or the front brake hose fitting. 9. Connect the brake pipe to the ABS modulator and tighten the flare nut. Tighten to 20 N.m (15 lb ft). 10. Connect the brake pipe to the left front caliper brake hose fitting. Tighten lighten the flare nut to 20 N.m (15 lb ft). 11. Position the wiring harness to the frame and secure in the retainers. 12. Connect the wheel speed sensor harness connector. Important Do not drive the vehicle until the brake pedal feels firm. Do not reuse brake fluid that is used during bleeding. 13. Lower the vehicle as necessary to allow for manual bleeding of the left front brake assembly. Caution Refer to Brake Fluid Caution in the Cautions and Notices in the appropriate Service Manual. Notice Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices in the appropriate Service Manual. Notice When adding fluid to the brake master cylinder reservoir, use only DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination, which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Important Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm in the next step. 14. Fill the brake master cylinder reservoir with Delco Supreme 11(R), GM P/N 12377967, Canadian P/N 89021320, or equivalent DOT-3 brake fluid from a clean sealed brake fluid container. 15. Install the J 35589-A to the brake master cylinder reservoir. 16. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme 11(R) or equivalent DOT-3 brake fluid from a clean sealed brake fluid container as necessary to bring the level to approximately the half-full point. 17. Connect the J 29532, or equivalent, to the J 35589-A. 18. Charge the J 29532, or equivalent, air tank to 175-205 kPa (25-30 psi). 19. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. Page 477 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. A/T - Fluid Oil Cooler Flush Transmission Cooler: All Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Page 12379 Seat Rear Vertical Motor - Driver/Passenger Page 6831 Starter Motor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the left tire. 3. Working in the left fender area, remove the battery positive lead from the solenoid (1). 4. Remove the starter mount bolt and nut (1, 2). 5. Remove the starter motor. INSTALLATION PROCEDURE 1. Install the starter motor. 2. Install the starter motor mount bolt and nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the starter mount bolt and nut to 50 N.m (37 lb ft). A/T - Fluid Oil Cooler Flush Transmission Cooler: All Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Page 6014 Shift Solenoid: Diagrams 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Slde OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 2894 Page 6705 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 8166 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Locations Memory/Heated Seat Switches Page 5450 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Page 3964 10. With an upward motion, remove the BCM (1) from the rear electrical center. INSTALLATION PROCEDURE 1. Index the slots on the BCM (1) to the rear electrical center. 2. Using a downward motion, install the BCM to the rear electrical center. Page 12130 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 7447 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 11456 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 5584 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Page 12791 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9669 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 12932 Abbreviations And Meanings Part 21 Page 2687 14. Connect the cooling fan hub nut to the water pump shaft. 15. Install the J 41240 to the water pump pulley and tighten the cooling fan hub nut. Tighten the cooling fan hub nut to 56 Nm (41 ft. lbs.). 16. Connect the battery negative cable. Page 7684 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the grille. 6. Remove sensor bracket from bumper. 7. Remove the Connector Position Assurance (CPA) from both (2) electronic frontal sensor (EFS) connectors. IMPORTANT: This vehicle is equipped with two inflatable restraint electronic frontal sensors (EFS). When performing this procedure be sure to include both EFS's. 8. Disconnect both EFS connectors. Zone 2 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 1748 Abbreviations And Meanings Part 12 Page 215 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Only if necessary remove the fuel tank shield. IMPORTANT: Due to an access hole in the fuel tank shield, removal of the shield should not be necessary to access the fuel pressure service connection. 3. Remove the fuel pressure service connection cap, located near the fuel filter. 4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Turn ON the ignition. 6. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 8. Command the fuel pump ON with a scan tool. 9. Close the bleed valve on the fuel pressure gage. 10. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. Page 11809 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 13915 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 12185 Registered And Non-Registered Trademarks Part 4 Page 12377 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Part 2 Page 13034 Cigarette Lighter: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram Page 7316 Application Table Part 2 Page 4321 10. With an upward motion, disconnect the body wiring extension (1) from the rear electrical center. 11. Remove the body wiring extension from the vehicle. INSTALLATION PROCEDURE 1. Using a downward motion, install the body wiring extension (1) to the rear electrical center. IMPORTANT: Ensure the sliding latch is fully extended before connecting the body wiring extension to the rear electrical center. Page 13086 Page 8503 Control Assembly: Diagrams HVAC System - Automatic Blower Motor Control Processor-Auxiliary (Body Type VIN 6) Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 11828 Abbreviations And Meanings Part 13 Page 12020 WA711J/58 - WA722J/25 Page 12864 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 12516 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 8404 Abbreviations And Meanings Part 24 Page 5809 Fluid - Differential: Service and Repair Lubricant Replacement - Rear Drive Axle Lubricant Replacement - Rear Drive Axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Inspect the rear axle for leaks. Repair as necessary. 3. Clean the area around the rear axle fill plug. 4. Remove the rear axle fill plug. 5. Remove the rear axle drain plug. 6. Drain the lubricant into a suitable container. 7. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 8. Clean the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Page 7312 Application Table Part 3 Location View Page 5826 1. Install the ring gear to the differential case. 2. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the new ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten the ring gear bolts in sequence to 120 Nm (89 ft. lbs.). 4. Install the drive pinion bearing cups. 5. Determine the selective shim thickness for the pinion gear. 6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing onto the pinion. 8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. 10. Install the pinion to the axle housing. 11. Install the outer pinion bearing. 12. Install a new pinion oil seal using the J38694. 13. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. Page 11376 Disclaimer A/C - Stops Blowing Cold Air/Cycles ON and OFF Refrigerant: All Technical Service Bulletins A/C - Stops Blowing Cold Air/Cycles ON and OFF File In Section: 01 - HVAC Bulletin No.: 02-01-39-006A Date: May, 2003 INFORMATION Subject: Diagnosing Poor A/C Performance - A/C Stops Blowing Cold, A/C Cycles On and Off Models: 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL with Automatic or Manual HVAC Auxiliary Temperature Control (RPOs CJ2 or CJ3) This bulletin is being revised to include the underhood label part number. Please discard Corporate Bulletin Number 02-01-39-006 (Section 01 - HVAC). Some of the above listed vehicles may exhibit poor A/C performance due to an overcharged system. If the A/C system is overcharged, it may cause the A/C to stop blowing cold after extended idle or while driving in slow traffic at high ambient temperatures. It has been found that the underhood label containing the A/C charge specification is incorrect. The correct specification should read System Charge with Front and Rear -1.20 kg (2.65 lbs) Use this new charge specification whenever the A/C system is serviced. Install new label, P/N 15103173. Parts Information Parts are currently available from GMSPO. Disclaimer Page 3471 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 9905 Page 11134 Involved are certain 2002-2003 Chevrolet TrailBlazer EXT and GMC Envoy XL vehicles operated in corrosion areas and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For dealers with involved vehicles, a Campaign Initiation Detail Report (CIDR) containing the complete vehicle identification number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts Pre-Ship Information Important: Recall - Brake Pipe Scoring Technical Service Bulletin # 03025 Date: 030501 Recall - Brake Pipe Scoring File In Section: Product Recalls Bulletin No.: 03025 Date: May, 2003 PRODUCT SAFETY RECALL SUBJECT: 03025 - BRAKE PIPE SCORING MODELS: 2003 CHEVROLET TRAILBLAZER 2003 GMC ENVOY 2003 OLDSMOBILE BRAVADA CONDITION General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2003 model year Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles. On some of these vehicles, the front left brake pipe may have been scored during manufacturing. The brake pipe may lose strength at the score location due to corrosion and fatigue resulting from brake fluid pressure, vibration, and temperature changes. As a result of this, the brake pipe may eventually fracture at the score location. If the brake pipe were to fracture, brake pedal travel would be increased and front brake performance would be reduced. In these instances, braking would be limited to that available with the remaining half system (rear brakes). In all of the above cases, the brake light would illuminate after sufficient fluid leaked out of the system to activate the low fluid level switch in the master cylinder reservoir. These conditions would meet the half system requirements of MVSS 135. CORRECTION Dealers are to inspect the front left brake pipe and replace it, if necessary. VEHICLES INVOLVED Involved are certain 2003 Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Page 809 Page 10279 Speaker - LF I/P (With RPO Code UQA) Page 6350 6. Remove the bleeder valve and bleeder valve cap from the caliper body. 7. Remove the guide pins and guide pin sleeves from the anchor bracket. 8. Clean the following components with denatured alcohol. ^ The bleeder valve ^ The caliper bore ^ The caliper passages ^ The piston ^ The lining contact area on the anchor bracket. 9. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 10. Replace the piston or the caliper if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Corrosion in the caliper bore. Use crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore Notice: Refer to Fastener Notice in Service Precautions. 11. Replace the bleeder valve cap. ^ Tighten the bleeder valve to 12 Nm (110 inch lbs.). Assembly Procedure 1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake fluid. Locations Fuel Tank Pressure Sensor: Locations Fuel Tank Page 6997 Application Table Part 2 Page 2282 7. Remove the junction block bracket retaining bolts (1) and remove the junction block bracket from the vehicle. INSTALLATION PROCEDURE 1. Position the junction block bracket and install the bolts (1). Tighten Tighten the junction block bracket bolts to 6 N.m (53 lb in). 2. Align the wiring harnesses and install the fuse relay center. 3. Install the fuse relay center bolts (3). Tighten Tighten the relay center bolts to 6 N.m (53 lb in). Page 4243 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 7234 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 11995 Parts Information Repair Claim Information - Refer to the extent of the repair instructions as approved by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) Warranty Information (excluding Saab U.S. Models) Page 10030 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 6149 Brake Pedal Assy: Service and Repair Brake Pedal Replacement Removal Procedure 1. Remove the closeout/insulator panel. 2. Remove the stoplamp switch from the brake pedal. 3. Remove the brake pedal pivot bolt and discard the bolt. 4. Remove the brake pedal. 5. Inspect the brake pedal pivot bushing for damage or wear. Installation Procedure 1. If the brake pedal pivot bushing is damaged or worn, replace the bushing using the following procedure: 1.1. Squeeze the end that will be facing the brake pedal pivot nut. 1.2. Insert the bushing into the pivot hub just enough to hold the bushing in place. 1.3. Push the bushing through the hub until the bushing snaps in place. 2. Install the brake pedal. Notice: Refer to Fastener Notice in Service Precautions. Important: The brake pedal pivot bolt is a prevailing torque bolt and must be replaced each time the bolt is removed. 3. Install the new brake pedal pivot bolt and the brake pedal pivot nut. ^ Tighten the brake pedal pivot bolt to 25 Nm (19 ft. lbs.). 4. Install the stoplamp switch to the brake pedal. 5. Install the closeout/insulator panel. Page 2415 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 13109 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 13518 Courtesy/Reading Lamp - RR Page 1504 29. Install the auxiliary heater pump and bracket onto the dash panel studs. 30. Reinstall the HVAC plate and nuts. 31. On the coolant bypass valve, remove the hose (1) that went from the valve to the engine and discard. ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Two - Person Procedure Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. Caution: Refer to Brake Dust Caution in Cautions and Notices. Important: ^ Use the two-person bleed procedure under the following conditions. Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake Pressure Modulator Valve (BPMV). - Air is trapped in the valve body. ^ Do not drive the vehicle until the brake pedal feels firm. ^ Do not reuse brake fluid that is used during bleeding. ^ Use the vacuum, the pressure and the gravity bleeding procedures only for base brake bleeding. 1. Raise the vehicle in order to access the system bleed screws. . Bleed the system at the right rear wheel first. 3. Install a clear hose on the bleed screw. 4. Immerse the opposite end of the hose into a container partially tilled with clean DOT 3 brake fluid. 5. Open the bleed screw 1/2 to 1 full turn. 6. Slowly depress the brake pedal. While the pedal is depressed to its full extent, tighten the bleed screw. 7. Release the brake pedal and wait 10-15 seconds for the master cylinder pistons to return to the home position. 8. Repeat the previous steps for the remaining wheels. The brake fluid which is present at each bleed screw should be clean and free of air. 9. This procedure may use more than a pint of fluid per wheel. Check the master cylinder fluid level every four to six strokes of the brake pedal in order to avoid running the system dry. 10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure. Release the brake pedal between each test. 11. Bleed all four wheels again using Steps 3-9. This will remove the remaining air from the brake system. 12. Evaluate the feel of the brake pedal before attempting to drive the vehicle. 13. Bleed the system as many times as necessary in order to obtain the appropriate feel of the pedal. Page 7810 6. Install J1859-A and J-36541-A to the steering wheel. 7. Remove the steering wheel using J1859-A and J-3654 1-A. Installation Procedure 1. Install the steering wheel to the steering wheel shaft. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining nut that secures the steering wheel to the steering wheel shaft. Tighten the retaining nut to 41 Nm (30 ft. lbs.). 3. Connect the steering wheel electrical connector. 4. Install the horn plunger to the steering column. 5. Install the inflator module. 6. Enable the SIR system. Page 5496 For vehicles repaired under warranty, use the table. Disclaimer Page 12362 Memory Seat Module - Passenger C2 Page 12487 Page 13223 Lubricant Level Inspection - Rear Drive Axle Fluid - Differential: Service and Repair Lubricant Level Inspection - Rear Drive Axle Lubricant Level Inspection - Rear Drive Axle 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. Specification The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. Page 67 Abbreviations And Meanings Part 12 Page 10303 Page 11043 7. Pass the feed wire (1) through the hinge (2), body pillar (3) and backing plate (4). 8. Crimp the feed wire (1) behind the backing plate. 9. Pull the feed wire 1) while guiding the backing plate (2) into the inner structure. 10. Place the hinge (1) into position and hand tighten the two attaching bolts. 11. Remove the feed wire (1) from the hinge. Page 9054 Tighten Tighten the front seat belt buckle nut to 52 N.m (38 lb ft). 3. Connect the seat belt reminder wiring harness (3) on the driver's seat. 4. Install the front seat assembly. Buckle Replacement - Center Rear REMOVAL PROCEDURE 1. Adjust the left rear seat back to a cargo position. 2. Adjust the seat filler panel on the bottom of the seat back in order to access the center rear seat back mounting nut. 3. Remove the rear seat back mounting nut. 4. Return the seat to an upright position. 5. Remove the clip(s) that retain the seat belt buckle anchor plate to the latch bracket. 6. Remove the seat belt buckle/anchor plate from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt buckle/anchor plate to the vehicle. 2. Install the clip(s) that retain the seat belt buckle/anchor plate to the latch bracket. 3. Adjust the left seat back to a cargo position. Page 8086 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 4827 Ignition Coil: Description and Operation Each ignition coil has an ignition 1 feed and a ground. The PCM supplies an ignition control (IC) circuit. Each ignition coil contains a solid state driver module as its primary element. The PCM signals the coil driver to initiate a firing event by applying the IC circuit voltage for the appropriate time or dwell. When the voltage is removed, the coil fires the spark plug. The coils are current-limited to prevent overloading if the IC current is held high too long. The spark plugs are tipped with platinum for long wear and higher efficiency. Page 2684 14. Note: Graphic shows left, right is similar. Remove the right engine mount bracket bolts. 15. Remove the right engine mount bracket. 16. Note: Graphic shows left, right is similar. Remove the right frame engine mount bracket bolts, if required. 17. Remove the right frame engine mount bracket, if required. Installation Procedure 1. Note: Graphic shows left, right is similar. Install the right frame engine mount bracket, if removed. NOTICE: Refer to Fastener Notice in Service Precautions. Page 7281 Abbreviations And Meanings Part 17 Page 664 Memory Seat Module - Driver C4 Part 3 Page 7345 Fuse Block - Underhood C1 Part 2 Page 13775 Tail Light Bulb: Service and Repair TAIL LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Remove the tail lamp assembly. 2. Place the tail lamp assembly onto a clean prepared surface. 3. Pull the bulb straight out in order to remove the tail lamp bulb from the socket assembly. INSTALLATION PROCEDURE 1. Install the tail lamp bulb to the socket assembly. 2. Ensure the bulbs are wiped clean and free of any oil or dirt. 3. Install the tail lamp assembly to the vehicle. 4. Check the bulbs for proper operation. Page 8930 10. Remove 2 TORX(R) head screws (2) from the upper shroud (1). 11. Remove the upper shroud (1). 12. Remove the wire harness straps from the steering wheel column wire harness. 13. Remove the retaining ring (3). 14. Remove the SIR coil (4) from the steering shaft. 15. If replacing, discard the SIR coil. INSTALLATION PROCEDURE 1. To install the SIR coil, perform the following procedure: 1.1. Aim the wheels straight ahead. Recall 03V151000: Front Brake Pipe Replacement Brake Hose/Line: Recalls Recall 03V151000: Front Brake Pipe Replacement DEFECT: Certain sport utility vehicles were built with a left-front brake pipe with a circumferential score at a random location along the length of the pipe as the result of the manufacturing process. If the brake pipe partially or fully fractured, brake pedal travel would immediately increase and front brake performance would be reduced, a crash could occur. REMEDY: Dealers will replace the left-front brake pipe. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners may contact Chevrolet at 1-800-222-1020, GMC at 1-800-462-8782, or Oldsmobile at 1-800-442-6537. Page 11243 Important: In any area with excessive damage, space the plug weld holes every 40 mm (11/2 in) apart. 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all of the attachment surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 4. Position the hinge bracket 5. Plug weld accordingly. 6. Clean and prepare all of the welded surfaces. Important: Prior to refinishing, refer to publication GM 4901M-2001 GM Approved Refinish Materials for recommended products. Do not combine the paint systems. Refer to the paint manufacturer's recommendation. 7. Apply the following as necessary: Page 5123 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Page 3357 2. Reposition the inlet radiator hose clamp at the thermostat (1) using J 38185. 3. Remove the inlet radiator hose from the thermostat. 4. Raise the vehicle. Refer to Vehicle Lifting. See: Service Precautions/Technician Safety Information/Vehicle Lifting Caution 5. Remove the lower radiator support shield, if equipped. 6. Reposition the inlet radiator hose clamp at the radiator using J 38185. 7. Remove the inlet radiator hose (1) from the radiator. Installation Procedure 1. Install the inlet radiator hose clamps to the radiator hose (1). 2. Install the inlet radiator hose (1) to the radiator. 3. Reposition the inlet radiator hose clamp using J 38185. Page 7318 Location View Page 5147 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install TCC PWM solenoid retainer. A/T - Shift Lock Control Actuator Available Shift Interlock Solenoid: Technical Service Bulletins A/T - Shift Lock Control Actuator Available Bulletin No.: 05-07-129-001B Date: February 16, 2007 INFORMATION Subject: Automatic Transmission Shift Lock Control Actuator Available for Service Use Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2006 Chevrolet TrailBlazer EXT 2003-2006 Chevrolet SSR 2002-2007 GMC Envoy 2002-2006 GMC Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add the SSR. Please discard Corporate Bulletin Number 05-07-129-001A (Section 07 - Transmission/Transaxle). The automatic transmission shift lock control actuator is now available for service as a separate part. The actuator was formerly available only as part of the entire shifter assembly. DO NOT replace the shifter assembly if the shift lock control actuator requires replacement. Please refer to the Automatic Transmission Shift Lock Control Actuator Replacement procedure in the Automatic Transmission sub-section of the Service Information. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Electrical - SES Lamp ON/DTC's P0480/P0526/P1481/P1484 Radiator Cooling Fan Motor: All Technical Service Bulletins Electrical - SES Lamp ON/DTC's P0480/P0526/P1481/P1484 Bulletin No.: 05-06-02-012B Date: October 19, 2006 TECHNICAL Subject: Service Engine Soon (SES) or Check Engine Light On, DTC P0480/P0526/P1481/P1484 Set (Replace Engine Cooling Fan Wiring Harness) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2005-2006 GMC Envoy Denali, Envoy XL Denali 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add DTC P1484. Please discard Corporate Bulletin Number 05-06-02-012A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the Service Engine Soon (SES) or Check Engine light is illuminated. This condition may be intermittent and upon investigation, the technician may find either DTC P0480, P0526, P1481 or P1484 set. Cause This condition may be caused by the cooling fan harness chaffing against the plastic guide it routes through. This contact may damage the insulation of the wires enclosed in that harness. Correction Replace the engine cooling fan harness using the procedure listed below. Remove the cooling fan. Refer to the Cooling Fan and Shroud Replacement procedure in the Engine Cooling sub-section of SI. Place the cooling fan assembly on a bench. Disconnect the harness electrical connector from the cooling fan clutch. Remove the harness from the plastic guide while feeding the wires out of the slot. Before installing the new harness, wrap the affected area on the wires with electrical tape to keep the protective sleeve in place. Be sure to keep the tape Page 9316 Steering Wheel Controls Page 10615 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Accumulator: Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Recall - Spark Plug Misfire Condition Spark Plug: Recalls Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Page 9655 Page 95 Steps 1-4 Wheels/Tires - Use of Nitrogen Gas in Tires Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Page 2913 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 9195 Registered And Non-Registered Trademarks Part 2 Page 4424 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 2231 Fuse Block - Underhood C1 Part 4 Page 10309 Page 11080 Front Door Striker: By Symptom Technical Service Bulletin # 03-08-64-006C Date: 070329 Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Page 10831 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 13105 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 6875 Various symbols in order to describe different service operations. Page 6954 Fuse Block - Rear C2 Part 2 Page 8215 Mode Actuator Page 12310 Sunroof / Moonroof Module: Diagrams Sunroof Module C1 Page 12501 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 5716 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Page 3933 Abbreviations And Meanings Part 20 Page 1813 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Description and Operation Radiator Cap: Description and Operation Pressure Cap The pressure cap seals the cooling system, and contains a blow-off or pressure valve, and a vacuum or atmospheric valve. The pressure valve is held against the seat by a spring, which protects the radiator from excess cooling system pressure. The vacuum valve is held against the seat by a spring, which permits the opening of the valve to relieve the vacuum created in the cooling system as the coolant cools off. The vacuum, if not relieved, might cause the radiator and/or coolant hoses to collapse. The pressure cap allows cooling system pressure to build up as the temperature increases. As the pressure builds, the boiling point of the coolant increases. Engine coolant can be safely run at a temperature much higher than the boiling point of the coolant at atmospheric pressure. The hotter the coolant is, the faster the heat transfers from the radiator to the cooler, passing air. The pressure in the cooling system can get too high. When the cooling system pressure exceeds the rating of the pressure cap, the pressure valve opens, venting the excess pressure. As the engine cools down, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum causes the vacuum valve to open, allowing outside air into the surge tank. This equalizes the pressure in the cooling system with atmospheric pressure, preventing the radiator and coolant hoses from collapsing. Page 68 Abbreviations And Meanings Part 13 Page 3589 Powertrain Control Module (PCM) C3 Part 4 Page 3907 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 11717 1. Remove the cargo shelf. 2. Tumble the third row seats to the cargo position. 3. Remove the left body side window rear garnish molding. 4. Remove the left body side window forward garnish molding. 5. Remove the liftgate sill plate. 6. Remove the left rear door sill panel 7. Remove the lower seat belt anchor bolt. 8. Remove the auxiliary power outlet from the trim panel. 9. Release the five screws that retain the rear quarter trim panel to the body. 10. Remove the rear quarter trim panel from the vehicle. INSTALLATION PROCEDURE Page 1696 Service and Repair Grille: Service and Repair Grille Replacement (Chevrolet) Removal Procedure 1. Use a flat-bladed tool in order to release the clips that retain the grille to the headlamp panel. 2. Remove the grille from the vehicle. Installation Procedure 1. Install the grille to the vehicle. 2. Align the retaining clips on the grille with the slots in the headlamp panel assembly. 3. Fully install the retaining clips into the headlamp panel. Page 1291 Miniwedge (Door Jamb Switch) - RF Page 6664 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 3215 approximately 25 mm (1 in) away from the connector so the wires can be fed into the slot. Feed the wires into the slot and install the harness to the plastic guide. Connect the harness electrical connector to the cooling fan clutch. Install the cooling fan. Refer to the Cooling Fan and Shroud Replacement procedure in the Engine Cooling sub-section of SI. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 12126 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 9825 Abbreviations And Meanings Part 17 Page 12084 includes paint technology, paint codes, trim level, and any special order paint colors. Parts ID Label Location LABEL - SERVICE PARTS ID Labeling - Service Parts ID The service parts identification label is located on the instrument panel storage compartment door in order to help service and parts personnel identify the vehicle's original parts and the vehicle's original options. Page 8519 4. Disconnect the electrical connectors (1) from the HVAC control module (2). INSTALLATION PROCEDURE 1. Connect the electrical connectors (1) to the HVAC control module (2). 2. Install the HVAC control module (2) into the IP (4). IMPORTANT:Ensure that the HVAC control module tabs (3) lock into place. 3. Install the HVAC control module screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to ......1.9 N.m (17 lb in). 4. Install the IP accessory trim plate. Page 4161 Steps 13-15 Page 1831 4. Loosen the lower control arm adjustment bolts (1). Adjust the caster and the camber angle by repositioning the lower control arm (2) until the specifications have been met. 5. When the adjustments are complete, hold the lower control arm in position so that the specifications do not change while tightening the lower control arm adjustment bolts. TIGHTEN ^ Front lower control arm bracket mounting bolts to 260 Nm (192 lb ft). ^ Rear lower control arm bracket mounting bolts to 240 Nm (177 lb ft). 6. Verify that the caster and the camber are still within specifications. When the caster and camber are within specifications, adjust the toe. Front Wheel Toe Adjustment Front Toe Adjustment 1. Loosen the jam nut on the outer tie rod (2). Notice: Care must be taken that the boots are not: twisted when rotating the inner tie rods, or damage to the boots may result. 2. Rotate the inner tie rod (1) to the required toe specification setting. 3. Tighten the jam nut on the outer tie rod. Tighten the outer tie rod jam nut to 75 Nm (55 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Electrical - Intermittent Interior Electrical Concerns Hazard Warning Flasher: All Technical Service Bulletins Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 5700 Valve Body Spring and Bore Plug Chart (inch) Page 13005 Abbreviations And Meanings Part 6 Page 1824 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Uneven brake adjustment ^ Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Page 11999 Disclaimer Technical Service Bulletin # 03-08-111-002G Date: 071221 Paint - Chips Behind Front Wheels/Front of Rear Wheels Bulletin No.: 03-08-111-002G Date: December 21, 2007 TECHNICAL Subject: Paint Chipping Behind Front wheels/Front of Rear Wheels Damaged Lower Door/Cladding and Rocker Panels (Repaint Damaged Area Install Assist Step) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2008 Chevrolet TrailBlazer 2006-2007 Chevrolet TrailBlazer 55 2002-2006 GMC Envoy XL 2002-2008 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Attention: Implementation of this Service Bulletin requires case-by-case review and approval by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) PRIOR to the performance of any repairs. Supercede: This bulletin is being revised to add the 2008 model year for TrailBlazer Envoy and Saab 9-7X models and change the refinish materials reference. Please discard Corporate Bulletin Number 03-08-111-002F (Section 08 - Body and Accessories). Condition Some customers may comment that the paint is chipped just behind the front wheels as well as just in front of the rear wheels. Some customers may also comment about damage to the lower door/cladding and rocker panels. Cause The rocker and lower door areas may be damaged by road debris thrown up by the tires at highway speeds. Correction It may be necessary to perform the following repair in order to meet customer expectations and gain their product satisfaction. Follow the manufacturers specifications for repainting the lower door/cladding and rocker panel and refer to the 2008 GMWI5406 GM Globally Approved Refinish Materials information for the type of paint and refinish materials to use. The refinish materials information is now online at the GMGOODWRENCH WEB SITE*. Printed books have been discontinued. To access the site follow these steps: Go to www.gmgoodwrench.com. Click on For Body Shops & Services link at the bottom of the page. Click on GM Technical Repair Information. Click on Paint Shop tab. Select the applicable downloadable link of the GM Approved Refinish Materials Guide. *In Canada the 2008 GM Approved Refinish Materials information is also available on the GM infoNET under the Service and Body tab. Page 10026 Page 9516 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 64 Abbreviations And Meanings Part 9 Service and Repair Horn Switch: Service and Repair Horn Switch Replacement Removal Procedure Caution: Refer to Servicing the SIR System Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the Inflatable Restraint Steering Wheel module. 3. Remove the horn plunger from the steering column by pressing inward to the stop and rotating horn plunger 90 degrees. 4. Disconnect the horn contact plate:(2) captured screws (1, 4) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure Page 11447 Body Emblem: Service and Repair Emblem Replacement - Grille Removal Procedure 1. Remove the grille. 2. Place the grille on a clean, prepared surface. 3. Remove the emblem retaining nuts. 4. Remove the emblem from the grille. Installation Procedure 1. Install the emblem to the grille. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the nuts that retain the emblem to the grille. Tighten the nuts to 3 N.m (27 lb in). 3. Install the grille. Page 11591 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Page 4976 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 6635 Steering - Steering Column Squeaking/Rubbing Noise Steering Shaft: Customer Interest Steering - Steering Column Squeaking/Rubbing Noise Bulletin No.: 02-02-35-006B Date: March 17, 2006 TECHNICAL Subject: Squeak, Rub/Scrub Type Noise in Steering Column (Lubricate Upper Intermediate Shaft Serration (Slip) Joint and Remove Material from Upper Intermediate Shaft Bushing) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to change the lubricant part number. Please discard Corporate Bulletin Number 02-02-35-006A (Section 02 - Steering). Condition Some customers may comment on a squeak noise coming from the steering column while turning the steering wheel. Some customers may also comment on a rubbing/scrubbing type noise/feel in the steering wheel during low speed turns/parking maneuvers. This condition may be more pronounced in cold temperatures. The rubbing/scrubbing noise condition affects vehicles built prior to VIN breakpoint 32214010 (Moraine, OH) and 36170447 (Oklahoma City, OK). Cause Inadequate distribution and amount of grease in the serration (slip) joint of the upper intermediate shaft may cause the squeak noise. The rubbing/scrubbing type noise may be due to an interference fit between the upper intermediate shaft boot seal and the intermediate shaft bushing. Correction Lubricate the upper intermediate shaft serration (slip) joint. After lubrication, remove material from the upper intermediate shaft bushing. Use the following procedure. 1. Remove the two screws that retain the left closeout/insulator panel to the instrument panel (IP). 2. Release the insulator panel retaining clip from the IP substrate and lower the panel. 3. Remove the push pin retainer and the LH floor air outlet duct from the heater module. 4. Insert the flexible applicator hose of the spray lubricant, P/N 89021668 (Canadian P/N 89021674), through the top, hollow end (1) of the intermediate shaft. Hinge Replacement - Rear Door - Body Side Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door - Body Side Hinge Replacement - Rear Door - Body Side Removal Procedure The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all. 1. Remove all of the related panels and components. 2. Remove the sealer surrounding the hinge (1). 3. Scribe the location of the hinge (1). 4. Hand-sand the existing hinge (1) with 100-grit sandpaper to locate the four weld locations. Page 6807 Abbreviations And Meanings Part 11 Page 2769 Oil Pressure Gauge: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: All Technical Service Bulletins Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 9146 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 11603 Tighten the bolts to 35 N.m (26 lb ft). 21. Install the rear side door sill plates. 22. Install the second row seats. 23. Install the third row seats. 24. Install the luggage/cargo shade assembly, if equipped. 25. Install the cargo net, if equipped. 26. Install the front seats. Carpet Replacement - Rear (TrailBlazer, Envoy, Bravada) Carpet Replacement - Rear (TrailBlazer, Envoy, Bravada) Removal Procedure 1. Remove the front seats. 2. Remove the rear seat cushions. 3. Remove the communication interface module. 4. Remove the navigation control processor bracket. 5. Remove the seat back, left and right side. 6. Remove the front bucket seats. 7. Remove the front door sill plates. 8. Remove the rear door sill plates. 9. Remove the lift gate door sill plate. 10. Remove the center pillar trim panels. 11. Remove the lower rear quarter trim panels. 12. Remove the tool kit carrier. 13. Remove the bussed electrical center junction block from the bussed electrical center base, and the bussed electrical center base from the floor panel studs. 14. Remove the child restraint tether anchors. 15. Remove the bussed electrical center base and communication interface module electrical connectors through the pass through holes in the carpet. 16. Remove the floor console to the floor console carrier. 17. Remove the four nuts retaining the rear of the floor console bracket to the floor weld studs. 18. Raise the rear portion of the floor console bracket and remove the carpet from underneath the console bracket. 19. Remove the carpet from the vehicle. Installation Procedure Page 11805 Various symbols in order to describe different service operations. Page 4285 Abbreviations And Meanings Part 19 Page 10900 Body Control Module (BCM) C1 Part 1 Page 11638 11. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 12. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 13. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 14. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 9 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 545 Page 6340 11. Remove the guide pin seals from the brake caliper mounting bracket. 12. Inspect the brake rotor. Installation Procedure 1. Install the guide pin seals on the mounting bracket. 2. If the guide pins and brake pad retaining clips are to be reused, use denatured alcohol to clean them. 3. Dry the brake guide pins and brake pad retaining clips with non-lubricated, filtered air. 4. Apply high temperature silicone brake lubricant to the brake caliper guide pins. DO NOT apply the lubricant to the brake pad retaining clips. Page 1942 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Turn OFF the ignition switch. 2. Remove the ignition coils. Refer to Ignition Coil Replacement. Notice: Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. Notice: Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure Notice: Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. Notice: Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gauge to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. Refer to Ignition System Specifications, See: Specifications Correct as necessary. Notice: Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Accessory Delay Module DIAGNOSTIC STARTING POINT - ACCESSORY DELAY MODULE Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The Diagnostic System Check will provide the following information: - Class 2 communication status - "U" codes which indicate module communication or circuit failure - "B" codes which indicate a possible body function or circuit failure - The status of any "U" or "B" codes Diagnostic System Check - Accessory Delay Module DIAGNOSTIC SYSTEM CHECK - ACCESSORY POWER MODULE TEST DESCRIPTION Steps 1-3 Page 13962 Registered And Non-Registered Trademarks Part 6 Page 7733 6. Remove the lower intermediate shaft retaining bolt from the power steering gear. 7. Disconnect the lower intermediate shaft from the power steering gear. 8. Remove the steering gear crossmember. 9. Remove the power steering hose assembly to the power steering gear retaining bolt. 10. Remove the power steering hose assembly from the power steering gear. 11. Support the power steering gear. 12. Remove the power steering gear mounting bolts. 13. Remove the power steering gear from the vehicle. 14. Remove the outer tie rods (2) from the inner tie rods (3). Installation Procedure Page 4119 Abbreviations And Meanings Part 5 Page 2766 Page 2677 6. Remove the right and the left upper engine mount nuts. 7. Raise the vehicle. Refer to Vehicle Lifting. 8. Remove the right and the left lower engine mount nuts. 9. Remove the engine protection shield mount bolts. 10. Remove the engine protection shield. Important: When placing jack onto the oil pan, pay close attention to not damage the oil level sender. 11. Lower the vehicle and place a floor jack under the oil pan with a block of wood. 12. Raise the engine with the jack just enough to clear the engine mount studs. 13. Remove the left engine mount from the bracket. Page 197 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 12053 WA519F/12 - WA519F/12 Page 12806 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Specifications Parking Brake Cable: Specifications Park Brake Cable Attaching Nuts 12.6 ft. lbs. Page 12996 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 2166 Brake Bleeding: Service and Repair Pressure Bleeding Procedure Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder- loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 35589-A. 8. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 8722 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. .................................................................... R-134a Page 9518 Page 3693 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. 2. Install the APP sensor retaining fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 3146 Water Pump: Description and Operation Water Pump The water pump is a centrifugal vane impeller type pump. The pump consists of a housing with coolant inlet and outlet passages and an impeller. The impeller is mounted on the pump shaft and consists of a series of flat or curved blades or vanes on a flat plate. When the impeller rotates, the coolant between the vanes is thrown outward by centrifugal force. The impeller shaft is supported by one or more sealed bearings. The sealed bearings never need to be lubricated. Grease cannot leak out, dirt and water cannot get in as long as the seal is not damaged or worn. The purpose of the water pump is to circulate coolant throughout the cooling system. The water pump is driven by the crankshaft via the drive belt. Page 12076 WA8624/50 - WA882K/90 Page 12550 Abbreviations And Meanings Part 18 Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: All Technical Service Bulletins Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Page 13901 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 3508 Abbreviations And Meanings Part 25 Page 137 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 9194 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 1941 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Cooling System - Electro-Viscous Fan Clutch Operation Fan Clutch: All Technical Service Bulletins Cooling System - Electro-Viscous Fan Clutch Operation Bulletin No.: 06-06-02-003 Date: February 14, 2006 INFORMATION Subject: Operating Characteristics of the Electro-Viscous (EV) Fan Clutch and Diagnostic Tips for Cooling Fan Noise, Delayed Transmission Shifts and/or Engine Revving Too High Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer SS 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X with 4.2L I-6, 5.3L V-8 or 6.0L V-8 Engine (VINs S, P, M, H - RPOs LL8, LM4, LH6, LS2) Date/VIN Breakpoints for Vehicles with New EV Fan Clutch Vehicles built after and including the Date or VIN Breakpoints listed in the table shown are equipped with the new electro-viscous (EV) fan clutch. Vehicles of any model year listed in "Models Affected" with labor code J3390 (claimed after June 8, 2005) with P/N 15293048 in Claim History may also be equipped with this new EV fan clutch. After having service for poor HVAC performance and/or engine cooling performance, some vehicles may exhibit fan noise, delayed transmission shifts, or the engine revving too high. These conditions may be caused by expected operating characteristics of the new design electro-viscous (EV) fan clutch. This new design EV fan clutch has been installed on production vehicles from the end of 2005 model year production (June 2005) and all 2006 model year vehicles. The new design EV fan clutch may also be present on vehicles serviced with this new part per Corporate Bulletin Number 04-01-38-019A or for other service related conditions. The updated design of the electro-viscous (EV) fan clutch helps improve A/C performance but may also produce some additional fan engagement noise. Important: Unless a specific issue is identified by proper SI diagnosis, do NOT replace a fan clutch for fan noise. Page 3968 10. With an upward motion, disconnect the body wiring extension (1) from the rear electrical center. 11. Remove the body wiring extension from the vehicle. INSTALLATION PROCEDURE 1. Using a downward motion, install the body wiring extension (1) to the rear electrical center. IMPORTANT: Ensure the sliding latch is fully extended before connecting the body wiring extension to the rear electrical center. Locations Engine, Left Side Page 2917 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 1123 Lumbar Adjuster Switch - Passenger (w/Heat) Page 521 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 11691 2. Lower the headliner in order to gain access to the wire harness. 3. Position the sunshade to the headliner. 4. Connect the sunshade electrical connector to the headliner harness. 5. Using a glue gun, hot melt the electrical connectors (1) to the headliner substrate, ensuring the connectors are securely attached to the substrate. 6. Route the wire harness until fully seated into the sunshade wire harness channel located on the pivot arm. 7. Position the wire harness retaining clip between the headliner and the roof panel. IMPORTANT: If the wire harness retaining clip is removed from the sunshade for any reason, a new retaining clip must be installed. 8. Position the index tabs on the wire harness retaining clip to the pivot arm and install the clip until fully seated. With the wire harness retaining clip installed, the sunshade should remain attached to the headliner. Page 12079 WA9260/74 - WA9260/74 Page 13095 Driver/Vehicle Information Display: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 6891 Abbreviations And Meanings Part 6 Page 2033 13. Connect the compressor hose assembly hose to the compressor (4). 14. Install the compressor hose assembly washers. 15. Install the retaining nut (3). Tighten Tighten the nut to .....33 N.m (24 lb ft). 16. Evacuate and recharge the A/C system. 17. Leak test the fittings of the components using the J 39400. Page 9145 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Recall - Spark Plug Misfire Condition Spark Plug: All Technical Service Bulletins Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 12838 Abbreviations And Meanings Part 15 Page 2656 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Drive Belt Falls Off Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. The drive belt may have been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Page 12542 Abbreviations And Meanings Part 10 Page 446 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 6199 English Prevailing Torque Fastener Minimum Torque Development Part 1 Recall 04V527000: Stop/Tail Lamp Inspect/Replace Brake Lamp: Recalls Recall 04V527000: Stop/Tail Lamp Inspect/Replace Make / Models : Model/Build Years: Buick / Rainier 2004 Chevrolet / TrailBlazer 2002-2004 Chevrolet / TrailBlazer ext 2002-2004 GMC / Envoy XL 2002-2004 Oldsmobile / Bravada 2002-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V527000 Recall Date : OCT 27, 2004 COMPONENT: EXTERIOR Lighting: Brake Lights Potential Number Of Units Affected : 871473 SUMMARY: On certain sport utility vehicles, vibration and heat may cause the tail lamp/stop lamp bulb to loosen in its socket. If this occurs, the bulb may flicker and eventually become inoperative. CONSEQUENCE: An inoperative brake lamp will not convey the driver's intention of stopping to drivers in following vehicles, and an inoperative rear turn signal lamp will not convey the driver's intention to turn to drivers in following vehicles. Both of these failures can increase the risk of a crash. REMEDY: Dealers will inspect the tail lamp/stop lamp assemblies, and if necessary, replace them. the recall began on November 22, 2004. Owners should contact Chevrolet at 1-800-630-2438, Oldsmobile at 1-800-630-6537, Buick at 1-866-608-8080, or GMC at 1-866-996-9463. NOTES: GM Recall NO. 04087. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 10386 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms - Accessory Delay Module SYMPTOMS - ACCESSORY DELAY MODULE IMPORTANT PRELIMINARY CHECKS BEFORE STARTING 1. Perform the Diagnostic System Check - Accessory Delay Module before using the Symptom Tables in order to verify that all of the following are true: There are no DTCs set. - The control module(s) can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Accessory Delay Module 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory power (RAP) Description and Operation. VISUAL/PHYSICAL INSPECTION - Inspect for aftermarket devices which could affect the operation of the Accessory Delay Module system. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout (with Relay)Retained Accessory Power (RAP) On After Timeout (No Relay, Class 2) - Retained Accessory Power (RAP) Inoperative (with relay)Retained Accessory Power (RAP) Inoperative (No Relay Class 2) Page 9836 Registered And Non-Registered Trademarks Part 2 Page 13874 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Recall - Spark Plug Misfire Condition Spark Plug: All Technical Service Bulletins Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Page 11218 4. Install the rear door sill plate. Page 4709 3. Remove the fuel fill pipe bracket nut (2). 4. Raise and suitably support the vehicle. 5. Remove the fuel fill pipe ground strap bolt. 6. Cut off the ground strap ring terminal and tie strap. 7. Loosen the fuel hose clamp (8). 8. Remove the fuel fill upper pipe (7) from the vehicle. 9. Install the new fuel fill upper pipe into the vehicle. Use P/N 88983256 for 2002-2003 model year vehicles or P/N 15131043 for 2004 model year vehicles. 10. Tighten the fuel hose clamp. Tighten Tighten the clamp to 2.5 N.m (22 lb in). 11. Wrap the excess length of ground strap around the fuel hose as necessary. 12. Install the fuel fill pipe ground strap bolt in its original location. 13. Loosen the fuel hose clamps (1, 3). 14. Remove the lower fuel hose (2) from the vehicle. 15. Install the new lower fuel hose into the vehicle. 16. Tighten the lower fuel hose clamps. Tighten Page 9622 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 9776 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 623 Driver Door Module (DDM) - C2 Part 1 Page 10494 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Locations Cruise Control Switch (Multifunction Switch) Page 13152 Abbreviations And Meanings Part 24 Page 7984 6. Install the shock module yoke to lower control arm retaining nut. Tighten the shock module yoke to lower control arm retaining nut to 110 Nm (81 ft. lbs.). 7. Install the tire and wheel. 8. Lower the vehicle. Shock, Shock Component, and/or Spring Replacement Shock, Shock Component, and/or Spring Replacement Tools Required ^ J45400 Strut spring compressor Removal Procedure Notice: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the shock module from the vehicle. 4. Remove the shock module yoke to shock absorber pinch bolt and nut. 5. Spread the shock module yoke at the pinch bolt using a flat bladed tool. 6. Remove the shock module yoke from the shock absorber. Page 12433 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 9508 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 1868 Disclaimer Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 3954 Body Control Module (BCM) C3 Part 3 Page 12937 Abbreviations And Meanings Part 26 Page 5702 Page 3489 Abbreviations And Meanings Part 6 Quick Connect Fitting(S) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Metal Collar) TOOL REQUIRED J 37088-A Fuel Line Disconnect Tool Set REMOVAL PROCEDURE 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief Procedure. 2. Remove the retainer from the quick-connect fitting. 3. Blow dirt out of the fitting using compressed air. CAUTION: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 4. Choose the correct tool from the J 37088-A for the size of the fitting. Insert the tool into the female connector, then push inward in order to release Page 12532 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 11154 Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown this bulletin). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Page 9999 Page 6024 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 6933 Application Table Part 3 Location View Page 12143 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 10680 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 5137 6. Remove the 1-2 and 2-3 Shift solenoid retainers. 7. Remove the 1-2 and 2-3 Shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 4696 4. Connect the chassis fuel feed pipe (3) to the fuel filter. 5. Connect the engine chassis fuel return pipe (1) to the fuel tank fuel return pipe. 6. Connect the chassis EVAP purge pipe (2) to the EVAP canister (1). 7. Use the following procedure with two wheel drive (2WD): 7.1. Position the EVAP/fuel hose/pipe assembly against the transmission and install the retaining bolt (3) through the EVAP/fuel hose/pipe assembly strap into the transmission. Page 10122 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 323 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 13023 Abbreviations And Meanings Part 24 Page 6885 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 4655 Steps 8-9 Page 6883 English Prevailing Torque Fastener Minimum Torque Development Part 1 Liftgate Module (LGM) Power Trunk / Liftgate Control Module: Diagrams Liftgate Module (LGM) Liftgate Module (LGM) C1 (Except XUV) Page 7456 C100 Part 2 Page 7873 3. Connect the air spring level sensor electrical connector. Notice: Failure to remove the air suspension auto level control sensor locating pin before the rear axle support is removed will cause damage to the air suspension auto level control sensor. 4. Remove the air spring level sensor locating pin. 5. Remove the rear axle support. 6. Install the rear tire and wheels. 7. Lower the vehicle. 8. Install the air suspension system fuse. 9. Start the vehicle and run for approximately 1 minute to ensure that the air spring leveling system is functioning properly. 10. Check the D height. Page 9619 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 12115 Page 4035 Powertrain Control Module (PCM) C1 Part 2 Page 1772 Window Switch - RR Part 2 Page 5833 14. Install the pinion yoke. Align the marks made during removal. 15. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 16. Install the washer and a new pinion nut. 17. Install the J8614-01 onto the pinion yoke as shown. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 18. Tighten the pinion nut while holding the J8614-0 1. Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 19. Measure the rotating torque of the pinion using an inch-pound torque wrench. Specification The rotating torque of the pinion should be 1.0 - 2.3 Nm (10 - 20 inch lbs.) for used bearings or 1.7 - 3.4 Nm (15 - 30 inch lbs.) for new bearings. 20. If the rotating torque measurement is below 1.0 Nm (10 inch lbs.) for used bearings, or 1.7 Nm (15 inch lbs.) for new bearings, continue to tighten the pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.0 - 2.3 Nm (10 - 20 inch lbs.) for used bearings or 1.7 - 3.4 Nm (15 - 30 inch lbs.) for new bearings. Page 1839 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 8270 8. Remove the outlet from the vehicle. INSTALLATION PROCEDURE 1. If reinstalling the original outlet, install the air deflectors in the outlet. 2. Install the outlet assembly to the I/P. 3. Install the 2 retaining screws (1). Tighten Tighten the screws to .....2.5 N.m (22 lb in). 4. Install the radio. 5. Install the I/P cluster bezel, Chevrolet only. 6. Install the knee bolster trim panel. Page 4267 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 6229 Registered And Non-Registered Trademarks Part 2 Page 6846 Page 11813 English Prevailing Torque Fastener Minimum Torque Development Part 1 Speaker - LF Door Speaker - LF Door ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Two - Person Procedure Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. Caution: Refer to Brake Dust Caution in Cautions and Notices. Important: ^ Use the two-person bleed procedure under the following conditions. Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake Pressure Modulator Valve (BPMV). - Air is trapped in the valve body. ^ Do not drive the vehicle until the brake pedal feels firm. ^ Do not reuse brake fluid that is used during bleeding. ^ Use the vacuum, the pressure and the gravity bleeding procedures only for base brake bleeding. 1. Raise the vehicle in order to access the system bleed screws. . Bleed the system at the right rear wheel first. 3. Install a clear hose on the bleed screw. 4. Immerse the opposite end of the hose into a container partially tilled with clean DOT 3 brake fluid. 5. Open the bleed screw 1/2 to 1 full turn. 6. Slowly depress the brake pedal. While the pedal is depressed to its full extent, tighten the bleed screw. 7. Release the brake pedal and wait 10-15 seconds for the master cylinder pistons to return to the home position. 8. Repeat the previous steps for the remaining wheels. The brake fluid which is present at each bleed screw should be clean and free of air. 9. This procedure may use more than a pint of fluid per wheel. Check the master cylinder fluid level every four to six strokes of the brake pedal in order to avoid running the system dry. 10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure. Release the brake pedal between each test. 11. Bleed all four wheels again using Steps 3-9. This will remove the remaining air from the brake system. 12. Evaluate the feel of the brake pedal before attempting to drive the vehicle. 13. Bleed the system as many times as necessary in order to obtain the appropriate feel of the pedal. Page 9077 Tighten the bolt to 70 N.m (52 lb ft). Page 7498 C401 (Body Type VIN 6) Part 2 Page 12186 Registered And Non-Registered Trademarks Part 5 Page 2900 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 3490 Abbreviations And Meanings Part 7 Page 10176 Antenna Extension Cable Replacement Antenna Cable: Service and Repair Antenna Extension Cable Replacement ANTENNA EXTENSION CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the inflatable restraint instrument panel (IP) module. 2. Disconnect the antenna cable (2) from the radio extension cable. 3. Remove the cable attachments (1) from the IP support bars. IMPORTANT: Note the location of the radio extension cable before removal. 4. Reach through the IP compartment to disconnect the antenna cable from the radio. 5. Remove the radio extension cable from the vehicle. INSTALLATION PROCEDURE Page 6505 Important: The spring clip kits mentioned in this bulletin do not address any parking brake concerns. Refer to the Parking Brakes sub-section of the Service Manual for any diagnostic information. Parts Information Parts are currently available from GMSPO. Warranty Information When removal of the rear brake rotors results in damage to the spring clips on vehicles under warranty, use the labor operation shown in conjunction with one of the kit part numbers listed above. Page 10418 Page 4247 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 9822 Abbreviations And Meanings Part 14 Page 4391 Engine Coolant Temperature (ECT) Sensor Page 9136 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Page 8638 3. Remove the heater outlet hose (3) from the heater core (1). 4. Position the outlet heater hose clamp (6) at the water pump using J 38185. 5. Remove the heater outlet hose (7) from the outlet hose fitting. 6. Remove the heater outlet hose. INSTALLATION PROCEDURE Page 13947 Abbreviations And Meanings Part 17 Page 8932 IMPORTANT: The new SIR coil will be pre-centered. Do not remove the centering tab from the new SIR coil until the installation is complete. 5. Firmly seat the retaining ring (3) into the groove on the steering shaft assembly (2). 6. Remove and discard the centering tab from the new SIR coil (4). 7. Install the upper shroud (1) and secure by using 2 TORX(r) head screws (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.5 N.m (13 lb in). 8. Install the lower shroud (2) and secure by using 2 TORX(r) head screws (1). Page 12717 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Page 10957 For vehicles repaired under warranty, use the table. Disclaimer Page 3467 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 2084 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. ^ Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. Page 12024 WA805K/62 - WA810K/48 Page 3969 2. Connect the 24-way gray electrical connector (1) to the BCM. 3. Connect the 32-way tan electrical connector (2) to the BCM. 4. Connect the body wiring extension (1) to the BCM. 5. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. Page 8283 Air Temperature Sensor-Upper Right Page 12052 WA423G/79 - WA519F/12 Page 6841 Page 3977 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 1673 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 8394 Abbreviations And Meanings Part 14 Specifications Luggage Rack: Specifications Fastener Tightening Specifications Page 140 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 12785 Page 7077 C100 Part 2 Page 8402 Abbreviations And Meanings Part 22 Page 9420 Page 3863 Body Control Module (BCM) Page 957 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. - Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. Removal Procedure 1. Loosen the PCM harness connector bolts (1) from the center of the PCM harness connectors. 2. Remove the PCM harness connectors (3) from the PCM (2). NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 3. Remove the PCM mounting nuts and bolts (4). 4. Remove the PCM (2) from the intake manifold. NOTE: Refer to PCM and ESD Notice in Service Precautions. 5. Remove the PCM mounting studs from the intake manifold, if necessary. Installation Procedure Page 13958 Registered And Non-Registered Trademarks Part 2 Steering - Hissing Noise From Steering Column Steering Shaft: Customer Interest Steering - Hissing Noise From Steering Column Bulletin No.: 05-02-35-006A Date: October 04, 2005 TECHNICAL Subject: Hiss/Rush Noise From Steering (STRG) Column Area (Replace Lower Intermediate Shaft) Models: 2004-2005 Buick Rainier Models 2002-2005 Chevrolet TrailBlazer Models 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada Models Supercede: This bulletin is being revised to correct the Labor Operation Number. The original bulletin incorrectly states to use Labor Operation E7770. The correct Labor Operation is E7700. Please discard Corporate Bulletin Number 05-02-35-006 (Section 02 - Steering). Condition Some customers may comment on a low volume hiss and/or rush noise heard from the steering column area. The noise may change when the steering wheel is rotated in either direction. The noise may be noticeable with the engine ON, vehicle in PARK, HVAC and Radio OFF. Cause The lower steering column intermediate shaft may be internally grounding out, creating a noise path. Diagnosis and Correction To determine if the lower intermediate shaft is allowing noise to travel from the power steering hydraulic system into the vehicle passenger compartment, follow the steps below. 1. Confirm the customer's concern. Note: Page 13451 Stop Lamp Switch Page 6365 Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. 1. Remove the air cleaner intake duct. 2. Disconnect the electrical connector from the fluid level sensor. 3. Using a pair of needle nose pliers, compress the locking tabs on the fluid level sensor Page 7785 1. Install the lower intermediate shaft to the vehicle. 2. Connect the lower intermediate shaft to the power steering gear. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the lower intermediate shaft to the power steering gear input shaft pinch bolt. Tighten the lower intermediate shaft to the power steering gear input shaft pinch bolt to 40 Nm (29 ft. lbs.). 4. Lower the vehicle. 5. Install the lower intermediate shaft boot and connect the lower intermediate shaft boot to the power steering gear. 6. Connect the lower intermediate shaft to the upper intermediate shaft. Notice: Refer to Fastener Notice in Service Precautions. 7. install the lower intermediate shaft to the upper intermediate shaft pinch bolt. Page 2360 Disclaimer Page 9151 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 2776 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 10035 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Diagrams Oil Level Sensor For ECM: Diagrams Engine Oil Level and Temperature Sensor Page 8401 Abbreviations And Meanings Part 21 Locations Page 10283 Speaker - RR Door Page 2545 2. Install fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1), which is part of EN 45680-400, over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117). Important: Use 4 old cylinder head bolts for the attaching bolts. 3. Insert the 4 attachment bolts into the legs of the fixture EN 45680-401(1). Note: Refer to Fastener Notice in Cautions and Notices. 4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore sleeve (117). Tighten Tighten the 4 attachment bolts to 15 N.m (11 lb ft). 5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100). Page 9980 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 12049 WA253A/86 - WA379E/86 Page 1659 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 6853 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Locations Automatic Transmission Page 9788 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 8572 For vehicles repaired under warranty, use the table. Disclaimer Page 10887 Abbreviations And Meanings Part 23 Page 6170 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Keyless Entry - System Inoperative Door Module: All Technical Service Bulletins Keyless Entry - System Inoperative Bulletin No.: 03-08-52-002 Date: March 27, 2003 TECHNICAL Subject: Remote Keyless Entry Inoperative (Reprogram Liftgate Module) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the Remote Keyless Entry (RKE) is inoperative at times. Cause An anomaly has been identified with the software in the Liftgate Module (RKE functions). The Liftgate Module software is affected when the temperature is approximately 40°C (104°F). Correction Using normal SPS reprogramming procedures, reprogram the LGM Liftgate module. The information was released on TIS version 2.75 or newer broadcast in March 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10312 Page 10628 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Application and ID Relay Box: Application and ID Location View Application Table Part 1 Page 1745 Abbreviations And Meanings Part 9 Page 12133 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 6789 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 9416 Page 4873 For vehicles repaired under warranty, use the table. Disclaimer Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 3411 3.3. Tighten the exhaust manifold bolts final pass in sequence to 20 Nm (15 ft. lbs.). 4. Install the exhaust manifold heat shield studs, if required. Tighten the heat shield studs to 10 Nm (89 inch lbs.). 5. Install the oxygen sensor. 6. Install the exhaust manifold heat shield. 7. Add anti-seize compound GM P/N 12371386 to the exhaust manifold heat shield nuts. 8. Install the exhaust manifold heat shield nuts. Tighten the exhaust manifold heat shield nuts to 5 Nm (44 inch lbs.). 9. Raise the vehicle. 10. Install the exhaust pipe to the manifold with seal and secure the pipe with the nuts. Tighten the exhaust pipe nuts to 50 Nm (37 ft. lbs.). Page 12188 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 907 3. Connect the 24-way gray electrical connector (1) to the BCM. 4. Connect the 32-way tan electrical connector (2) to the BCM. 5. Connect the 40-way body wiring extension (1) to the BCM. 6. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. Page 486 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 142 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 10674 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 1818 Frame Angle Measurement (Express / Savana Only) ........ Electronic Brake Control Module (EBCM) C1 Page 4458 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 1822 Page 11532 2. Install the transfer case shield mounting bolts (3). Tighten the transfer case shield mounting bolts to 16 N.m (12 lb ft). 3. Lower the vehicle. Refer to Vehicle Lifting. Page 3528 Door Control Module Diagram 3 Page 6206 Abbreviations And Meanings Part 5 Page 43 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 206 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 1331 Lifgate Ajar Switch Page 7114 C314 Locations Electronic Components Page 6634 Page 11772 Locations Accelerator Page 11037 5. Center punch each weld location (1). IMPORTANT: Drill through the hinge base only (1). Do not drill through the mating surface (2). Remove hinge tab (3) before drilling, if necessary. 6. At each punch location, drill a 3 mm (1/8 in.) pilot hole (1). 7. Using the pilot hole as a guide, drill through the hinge base using a 19 mm (3/4 in.) rotabroach hole saw or equivalent (2). IMPORTANT: If necessary, use a chisel to separate the hinge from the mating surface. 8. Remove the hinge. Recall - Brake Pipe Scoring Technical Service Bulletin # 03025 Date: 030501 Recall - Brake Pipe Scoring File In Section: Product Recalls Bulletin No.: 03025 Date: May, 2003 PRODUCT SAFETY RECALL SUBJECT: 03025 - BRAKE PIPE SCORING MODELS: 2003 CHEVROLET TRAILBLAZER 2003 GMC ENVOY 2003 OLDSMOBILE BRAVADA CONDITION General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2003 model year Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles. On some of these vehicles, the front left brake pipe may have been scored during manufacturing. The brake pipe may lose strength at the score location due to corrosion and fatigue resulting from brake fluid pressure, vibration, and temperature changes. As a result of this, the brake pipe may eventually fracture at the score location. If the brake pipe were to fracture, brake pedal travel would be increased and front brake performance would be reduced. In these instances, braking would be limited to that available with the remaining half system (rear brakes). In all of the above cases, the brake light would illuminate after sufficient fluid leaked out of the system to activate the low fluid level switch in the master cylinder reservoir. These conditions would meet the half system requirements of MVSS 135. CORRECTION Dealers are to inspect the front left brake pipe and replace it, if necessary. VEHICLES INVOLVED Involved are certain 2003 Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Suspension - Boom/Rumble Heard at Highway Speeds Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Suspension - Boom/Rumble Heard at Highway Speeds Bulletin No.: 02-03-09-002C Date: December 06, 2004 TECHNICAL Subject: Intermittent Boom, Rumbling Noise and/or Disturbance Heard in Passenger Compartment While Driving at Highway Speeds (Replace Rear Coil Springs) Models: 2002-2005 Chevrolet TrailBlazer 2002-2005 GMC Envoy with Rear Coil Springs 2003-2004 Oldsmobile Bravada with Rear Coil Springs Built Prior to August 23, 2004 (Refer to Parts Information table below for applicable RPO Code usage) Attention: Do not perform this bulletin for vehicles built after 8/23/04. Supercede: This bulletin is being revised to add the breakpoint of 8/23/2004 for 2005 model year production with an updated spring material. Please discard Corporate Bulletin Number 02-03-09-002B (Section 03 - Suspension). Condition Some customers may comment on an intermittent booming, rumbling noise and/or disturbance heard in the passenger compartment while driving the vehicle at highway speeds. This condition occurs while driving at steady speeds between 1550-1700 engine RPM in 4th gear (NOT during acceleration). This equates to 64-80 km/h (48-50 mph) for vehicles with a 4.10 axle ratio (RPO GT5), 83-86 km/h (52-54 mph) with a 3.73 axle ratio (RPO GT4) and 93-96 km/h (58-60 mph) with a 3.42 axle ratio (RPO GU6). Cause The noise/disturbance occurs when the torque converter momentarily goes to a full lock-up state, resulting in zero slip of the torque converter. When the torque converter returns to normal ECCC mode with 30 RPM of slip, the noise will go away. The disturbance generated by the zero slip condition is amplified and transferred into the passenger compartment by the rear coil springs. Correction Replace the rear coil springs using the following service procedure. Note: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 1. Raise and support the vehicle. 2. Support the front frame rail of the vehicle with a suitable adjustable jack stand. 3. Support the rear axle with a suitable adjustable jackstand. 4. Remove the two shock absorber lower mounting bolts. 5. Lower the rear axle enough to remove the tension on the rear coil springs. 6. Remove the rear coil springs. Important: ^ It is critical that the correct coil springs are installed in the correct location. Page 2650 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: - The drive belt - The drive belt tensioner - The drive belt idler pulley - The crankshaft balancer pulley - The accessory drive component mounting brackets - The accessory drive components + The power steering pump, if belt driven + The generator + The A/C compressor, if equipped + The engine cooling fan, if belt driven + The water pump, if belt driven + The vacuum pump, if equipped + The air compressor, if equipped The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers (chloroprene or EPDM) and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Page 6817 Abbreviations And Meanings Part 21 Page 4120 Abbreviations And Meanings Part 6 Page 11837 Abbreviations And Meanings Part 22 Page 3073 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator support diagonal brace if applicable. 2. Remove the radiator air intake baffle if applicable. 3. Loosen the three air cleaner cover/resonator retaining screws (2) one shown, and remove the cover/resonator (1). 4. Lift the air cleaner element (1) and air outlet duct (3) from the lower air cleaner housing/washer solvent tank assembly (2). 5. Remove the air cleaner element (1) by grasping the air cleaner element and removing it from the air outlet duct (3) with a twisting and pulling motion. 6. Inspect the entire assembly for debris or damage and repair as necessary. INSTALLATION PROCEDURE Page 799 9. Install the 3 bolts (1) that retain the junction block to the block base. Tighten Tighten the 3 bolts to 3.5 N.m (31 lb in). 10. Install the BCM to the rear electrical center. 11. Install the battery feed terminal nut (2) to the junction block. Tighten Tighten the battery feed terminal nut to 10 N.m (88 lb in). 12. Install the rear electrical center cover. 13. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a passenger position. 14. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 15. Connect the battery negative cable. Page 13145 Abbreviations And Meanings Part 17 Page 4697 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 3.75 N.m (33 lb in). 7.2. Install the EVAP/fuel hose/pipe assembly into the clip at the rear of the transmission. 8. Use the following procedure with four wheel drive (4WD): 8.1. Position the fuel EVAP/fuel hose/pipe assembly against the transmission and install the retaining bolt (3) through the EVAP/fuel hose/pipe assembly strap into the transmission. Tighten Tighten the bolt to 3.75 N.m (33 lb in). 8.2. Install the EVAP/fuel hose/pipe assembly into the clip at the rear of the transmission. 9. Install the EVAP/fuel hose/pipe assembly (4) into the EVAP/fuel hose/pipe assembly clip at the rear of the engine. 10. Connect the integral clip (3) to the engine bracket. 11. Connect the EVAP purge pipe (5) to the EVAP canister purge valve. 12. Lower the vehicle. 13. Connect the fuel feed (1) and fuel return (2) pipes to the fuel rail. 14. Connect the powertrain control module connectors to the powertrain control module. 15. Connect the negative battery cable. 16. Inspect for leaks using the following procedure: 16.1. Turn ON the ignition, with the engine OFF for 2 seconds. 16.2. Turn OFF the ignition, for 10 seconds. 16.3. Turn ON the ignition, with the engine OFF. Page 11579 Remove the auxiliary seal and the auxiliary seal retainer. Clean the surface and fill the void with Medium Body Seam Sealer, P/N 12378500 (in Canada, P/N 10952233). Let stand for 60 minutes and touch up. Correction 2 Remove the auxiliary seal and the auxiliary seal retainer. Clean the area with a non oil base cleaner and fill the void with urethane sealer. Correction 3 Install four new plastic nuts in the "A" Pillar. The new nuts have a foam gasket that seals the perimeter when seated. Correction 4 Seat the push-in retainers fully at the bottom of the "A" pillar. Correction 5 Apply weatherstrip adhesive inside the primary seal retainer. Seal the retainer from the top of the dash to the bottom of the "A" pillar. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 10130 Page 4781 Camshaft Position (CMP) Sensor Page 7764 For vehicles repaired under warranty, use the table. Disclaimer Page 12526 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 9765 Page 6157 Page 4262 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 9434 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 9392 Abbreviations And Meanings Part 26 Interior - Front Floor Carpet Is Wet Carpet: All Technical Service Bulletins Interior - Front Floor Carpet Is Wet TECHNICAL Bulletin No.: 03-08-57-004D Date: November 21, 2008 Subject: Front Floor Carpet Wet (Seal Top of "A" Pillar) Models: 2004-2007 Buick Rainier 2002-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2009 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 03-08-57-004C (Section 08 - Body and Accessories). Condition Some customers may comment that the front floor carpet is wet. Cause 1 Water may enter a hole in the seam sealer at the roof panel to upper "A" pillar post. In this case, the water enters the hole and leaks down the inside of the "A" pillar and ends up on the front floor. Refer to the illustration above. Cause 2 Water may enter the seam at the top of the "A" pillar. In this case, the water enters where the roof panel to upper "A" pillar meet and follows this seam under the windshield urethane. The water then drips onto the "A" pillar garnish molding and ends up on the floor. Refer to the illustration above. Cause 3 Front Suspension Strut / Shock Absorber: Service and Repair Front Shock Module Replacement This article has been updated by TSB# 06-03-08-011 dated August 28,2006. Shock Module Replacement Tools Required ^ J 36607 Ball Joint Separator Removal Procedure 1. Remove the shock module upper retaining nuts. 2. Raise and support the vehicle. Notice: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 3. Remove the tire and wheel. 4. Loosen the shock module yoke to lower control arm retaining nut. 5. Remove the shock module yoke from the lower control arm using J 36607. Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 10544 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 4687 Disclaimer Page 4719 5. Remove the fuel fill pipe ground strap bolt (3). 6. Loosen the fuel hose clamp (1). 7. Separate the fuel hose (2) from the tank. 8. Cap the open end of the fuel tank. 9. Remove the push pin fastener (5). 10. Remove the fuel filler pipe from the vehicle. INSTALLATION PROCEDURE Page 5190 ^ The 3-4 accumulator spring ^ The 3-4 accumulator pin 12. Remove the spacer plate support. 13. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. 14. Remove the 3-4 accumulator piston (2). 15. Inspect the 3-4 accumulator spring for cracks. 16. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. 17. Inspect the 3-4 accumulator piston for the following defects: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches Page 6774 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 5643 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Page 3345 Radiator: Service and Repair Body VIN Type 3 Radiator Replacement (Body Vin Type 3 / GMT 360) Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the coolant from the radiator. 2. Recover the refrigerant. 3. Raise the vehicle. Refer to Vehicle Lifting. See: Service Precautions/Technician Safety Information/Vehicle Lifting Caution 4. Remove the lower radiator support shield, if equipped. 5. Reposition the outlet radiator hose clamp using J 38185. 6. Remove the outlet radiator hose (1) from the radiator. 7. Remove the transmission cooler lines from the radiator. 8. Lower the vehicle. 9. Remove the cooling fan and shroud. 10. Remove the radiator support diagonal brace. 11. Remove the coolant recovery line from the radiator. Page 1001 29. Install the auxiliary heater pump and bracket onto the dash panel studs. 30. Reinstall the HVAC plate and nuts. 31. On the coolant bypass valve, remove the hose (1) that went from the valve to the engine and discard. Page 9422 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 2763 Page 6808 Abbreviations And Meanings Part 12 Page 4298 Registered And Non-Registered Trademarks Part 6 Page 4283 Abbreviations And Meanings Part 17 Page 13906 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 8201 Air Door Actuator / Motor: Locations HVAC Sytem - Manual Instrument Panel Carrier Page 7279 Abbreviations And Meanings Part 15 Page 6673 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 4608 Fuel Injector 3 Page 12884 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 7992 1. Install the shock absorber to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shock absorber lower mounting bolt. Tighten the shock absorber lower mounting bolt to 80 Nm (59 ft. lbs.). 3. Install the shock absorber upper mounting bolt. Tighten the shock absorber upper mounting bolt to 80 Nm (59 ft. lbs.). Important: Before removing the support from the rear axle, ensure that the air suspension leveling sensor link is in the correct position. If the air suspension leveling sensor link is out of position, air suspension system failure will occur. 4. Remove the support from the rear axle. 5. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when center punching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. Description and Operation ABS Light: Description and Operation ABS Indicator The IPC illuminates the ABS indicator when the following occurs: ^ The Electronic Brake Control Module (EBCM) detects an ABS-disabling malfunction. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check. ^ The IPC detects a loss of class 2 communications with the EBCM. Page 3504 Abbreviations And Meanings Part 21 Page 7828 1. Install the upper ball joint to steering knuckle using J9519-E, J21474-01, and J45117. 2. Install the upper ball joint retaining clip. 3. Install the steering knuckle with wheel hub attached. 4. Install the tire and wheel. 5. Lower the vehicle. 6. Check the front wheel alignment. Page 5378 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replace-Body VIN Code 6 LL8 Transmission Fluid Cooler Hose/Pipe Replacement (Body Vin Code 6 LL8) Removal Procedure 1. Disconnect the transmission cooler lines from the radiator. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Place a drain pan under the vehicle. 4. Remove the cooler lines (3,4) from the radiator. 5. Separate the front and rear cooler lines at the quick connect fitting (2). 6. Remove the cooler lines from the retainer (1) located on the radiator shroud. 7. Remove the front sections of the cooler lines from the vehicle. 8. Remove the rear sections of the cooler from the retainer (1) located on the tight side of the engine. 9. Remove the clip (2) that holds the cooler lines together. 10. Support the transmission with a transmission jack. 11. Remove the transmission support. 12. Remove the front exhaust pipe assembly. 13. Carefully lower the transmission to gain access to the cooler line fittings. 14. Disconnect the transmission cooler lines from the transmission. Page 12401 Seat Adjuster Switch Driver (w/o Memory) Part 2 Page 6657 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 2505 1. Install the exhaust camshaft actuator into the timing chain. 2. Align the marked link of the timing chain with the timing mark on the exhaust camshaft position actuator sprocket (1). Important: Ensure the alignment pin is engaged between the camshaft and the exhaust camshaft position actuator. 3. Install the exhaust camshaft actuator onto the exhaust camshaft. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Notice: The camshaft actuator must be fully advanced during installation. Engine damage may occur if the camshaft actuator is not fully advanced. Important: Ensure the camshaft actuator is rotated clockwise relative to the camshaft prior to tightening the bolt. Do not force the camshaft actuator to rotate clockwise. If it does not move easily, it is already fully advanced. New camshaft actuators are already packaged in the fully advanced (clockwise) position. 4. Install the exhaust camshaft actuator bolt. - Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 lb ft). - Use the J 36660-A to tighten the exhaust camshaft actuator bolt the final pass an additional 135 degrees. 5. Remove the J-44217. Page 13605 Turn Signal/Hazard Flasher Module Page 7696 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 4. Connect the IP module yellow 4-way connector (1) located behind the IP support. 5. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 4451 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 2 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must reinstall the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. 2. Install the heated oxygen sensor (2) using a J 39194-B. Page 8629 5. Install the HVAC module-auxiliary. Page 6189 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 11009 Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Journal Clearance 0.0008-0.0025 inch Page 9180 Abbreviations And Meanings Part 13 Page 2077 Disclaimer Page 13884 Page 1283 Ambient Light/Sunload Sensor Assembly Page 9827 Abbreviations And Meanings Part 19 Page 4821 Ignition Coil: Diagrams Ignition Coil 1 Page 9990 Circuit/System Testing Component Testing Page 13275 Abbreviations And Meanings Part 13 Page 9838 Registered And Non-Registered Trademarks Part 4 Page 12713 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 4071 Page 10044 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 8230 Air Door Actuator / Motor: Description and Operation HVAC System - Automatic HVAC SYSTEM - AUTOMATIC AIR DELIVERY DEFROST ACTUATOR The defrost actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage,low reference, control, 5 voltreference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range.When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. MODE ACTUATOR The mode actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5-volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range.When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. The mode actuator is an electronic stepper motor with feedback potentiometers. The HVAC control module sends signals to the mode door actuator through the mode door control circuit. Zero volts drives the actuator in one direction while 5 volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5 volt reference circuit to the mode actuator. When you select a desired mode setting, logic determines the value of the mode actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the mode door position signal circuit. The motor moves the mode door to the desired position. DEFROST ACTUATOR The defrost actuator operates the same as the mode actuator. The HVAC control module sends signals to the mode door actuator through the defrost door control circuit. Zero volts drives the actuator in one direction while 5 volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts,the actuator rotation stops. A 5-volt reference signal is sent out over the 5-voltreference circuit to the defrost actuator. When you select a defrost setting, logic determines the value of the defrost actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the defrost door position signal circuit. The motor moves the defrost door to the desired position. AIR TEMPERATURE AIR TEMPERATURE ACTUATOR The air temperature actuators are a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control,5 volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range.When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. Page 9682 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 4125 Abbreviations And Meanings Part 11 Page 5741 Page 10161 Page 2203 Fuse: Application and ID Underhood Fuse Block Location View Application Table Part 1 Page 1728 Conversion - English/Metric Part 2 Page 11693 Sun Visor: Removal and Replacement Sunshade Replacement Removal Procedure 1. Remove the windshield garnish molding. 2. Release the front assist handle from the headliner. Refer to Assist Handle Replacement. 3. Recline the bucket seat and release the upper portion of the center pillar trim panel. Refer to Garnish Molding Replacement - Center Pillar. 4. Open and rotate the sunshade parallel to the side window. 5. Insert a small tool into the bezel access hole (1). Important: Midway through the rotation cycle, the tool will move further into the access hole. 6. Push upward on the tool while rotating the sunshade parallel to the windshield. The sunshade pivot arm bezel should appear to be recessed into the bezel. Important: Ensure the pivot arm is recessed into the bezel before removing the sunshade from the headliner. 7. Apply outboard pressure to the sunshade while the sunshade is parallel to the windshield. Page 6713 Generator: Description and Operation GENERATOR The AD-244 generator is non-repairable. They are electrically similar to earlier models. The generator(s) feature the following major components: The delta stator - The rectifier bridge - The rotor with slip rings and brushes - A conventional pulley - Dual internal fans - A voltage regulator The pulley and the fan cool the slip ring and the frame. The AD stands for Air-cooled Dual internal fan; the 2 is an electrical design designator; the 44 denotes the outside diameter of the stator laminations in millimeters, over 100 millimeters. The generator is rated at 150 amperes. The generator features permanently lubricated bearings. Service should only include the tightening of mounting components. Otherwise, the generator is replaced as a complete unit. Page 11584 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 4639 7. Pull the connection apart. CAUTION: Refer to Relieving Fuel Pressure Caution in Service Precautions. INSTALLATION PROCEDURE 1. Apply a few drops of clean engine oil to the male connection end. CAUTION: Refer to Fuel Pipe Fitting Caution in Service Precautions. 2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place. 3. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure. Page 812 Page 8200 HVAC Module-Auxiliary (Body Type VIN 6) Page 12799 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 12132 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Procedures Power Door Lock Switch: Procedures Switch Replacement - Door Lock and Side Window - Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle INSTALLATION PROCEDURE 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. 4. If replacing the driver door module, program the driver door module. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming and Personalization Description and Operation in Personalization. IMPORTANT: When replacing the driver door module, the set up procedure must be performed. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 4583 Fuel: Service and Repair FUEL SYSTEM CLEANING 1. Remove the fuel sender assembly. 2. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet. 3. Flush the fuel tank with hot water. IMPORTANT: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state, and federal laws and regulations. 4. Pour the water out of the fuel sender assembly opening. Rock the tank to be sure that removal of the water from the tank is complete. 5. Install the fuel sender assembly. Page 12028 WA820K/94 - WA8554/40 Page 2103 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Above -18° C (0° F) ......................................... .......................................................................................................................... 10W-30, 5W-30 (preferred) Below -29° C (-20° F) ................................................................................................................................................. 5W-30 synthetic (preferred) , 0W-30 Page 1705 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 12288 Sunroof / Moonroof Motor: Service and Repair SUNROOF MOTOR/ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement (TrailBlazer, Envoy, Bravada)Headliner Replacement (TrailBlazer EXT, Envoy XL) in Interior Trim. 2. Remove the tie strap that retains the white connector to the drive cable tube sunroof motor wiring harness. 3. Disconnect the sunroof motor/actuator wiring harness electrical connector. 4. Remove the screws (1) which retain the sunroof motor/actuator (2) to the sunroof module assembly. 5. Remove the sunroof motor/actuator (2) from the sunroof module assembly. INSTALLATION PROCEDURE 1. Align the splines on the sunroof motor/actuator shaft with the drive gear on the sunroof module assembly. 2. Install the sunroof motor/actuator (2) to the mounting bracket, ensuring that the sunroof motor/actuator is fully seated. 3. Install the screws (1) that retain the sunroof motor/actuator (2) to the mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the sunroof motor/actuator screws to 3 N.m (27 lb in). 4. Connect the sunroof motor/actuator wiring harness electrical connector. 5. Install the tie strap retaining the sunroof motor/actuator wiring harness. 6. Install the headliner. Page 3256 For vehicles repaired under warranty, use the table. Disclaimer Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ....................................................... 2.65 lb. (1.2 kg.) Page 12655 Sunroof Switch Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: Customer Interest Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 13055 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 4. Install the LF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Page 13240 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 2757 OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 12561 Registered And Non-Registered Trademarks Part 3 Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 10121 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 7245 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 9131 Ride/Trim Height Inspection Procedure Alignment: Service and Repair Ride/Trim Height Inspection Procedure TRIM HEIGHT MEASUREMENTS Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following prior to measuring trim heights: ^ Make sure the vehicle is on a level surface, such as an alignment rack. ^ Set the tire pressures to specifications. ^ Check the fuel level. Add additional weight if necessary to simulate a full tank. ^ To ensure proper weight distribution make sure the rear storage compartment is empty. ^ Close the doors and hood. Z Height Measurement - Front The Z height measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm to adjust the Z height. Vehicles without torsion bars have no adjustment and may require replacement of suspension components. Important: All dimensions are measured vertical to the ground. 1. Place hands on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (3) down to the lower corner (5) of the lower ball joint (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation and measurement 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the high and the low measurements. Cross vehicle Z heights should be within 24 mm (0.9 inch). 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension. ^ Collision damage. D Height Measurement - Rear The D height measurement determines the proper ride height for the rear end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. Important: All dimensions are measured vertical to the ground. 1. Place hands on the rear bumper and jounce the rear of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. Page 4903 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Recall 04V527000: Stop/Tail Lamp Inspect/Replace Brake Lamp: All Technical Service Bulletins Recall 04V527000: Stop/Tail Lamp Inspect/Replace Make / Models : Model/Build Years: Buick / Rainier 2004 Chevrolet / TrailBlazer 2002-2004 Chevrolet / TrailBlazer ext 2002-2004 GMC / Envoy XL 2002-2004 Oldsmobile / Bravada 2002-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V527000 Recall Date : OCT 27, 2004 COMPONENT: EXTERIOR Lighting: Brake Lights Potential Number Of Units Affected : 871473 SUMMARY: On certain sport utility vehicles, vibration and heat may cause the tail lamp/stop lamp bulb to loosen in its socket. If this occurs, the bulb may flicker and eventually become inoperative. CONSEQUENCE: An inoperative brake lamp will not convey the driver's intention of stopping to drivers in following vehicles, and an inoperative rear turn signal lamp will not convey the driver's intention to turn to drivers in following vehicles. Both of these failures can increase the risk of a crash. REMEDY: Dealers will inspect the tail lamp/stop lamp assemblies, and if necessary, replace them. the recall began on November 22, 2004. Owners should contact Chevrolet at 1-800-630-2438, Oldsmobile at 1-800-630-6537, Buick at 1-866-608-8080, or GMC at 1-866-996-9463. NOTES: GM Recall NO. 04087. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 11537 Tighten the bolts to 50 N.m (37 lb ft). 2. Lower the vehicle. Page 944 Powertrain Control Module (PCM) C1 Part 4 Specifications Engine Oil Pressure: Specifications Oil Pressure (At the sending unit) Warm - Minimum 12 psi - 1200 RPM Page 69 Abbreviations And Meanings Part 14 Page 5701 Page 2008 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the fuel pressure service connection cap. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Install the fuel tank shield if removed. Page 8864 A/C Low Pressure Switch (w/Automatic - HVAC System) Page 548 Page 11770 Page 402 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 12157 Abbreviations And Meanings Part 2 Page 13183 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 6. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. 5. Access the I/P module connector through the glove box. Page 764 Involved are certain 2004 Buick Rainier, 2003-2004 Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts Pre-ship Information - For US Only Important: An initial supply of flashers required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of July 18, 2005, and will be approximately 10% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Page 8897 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Access IP module connector through glove box. 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 13058 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 4. Connect the IP module yellow 4-way connector (1) located behind the IP support. 5. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. Page 4452 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). 4. Lower the vehicle. Page 11884 Door Lock Actuator - LR Locations Lock Cylinder Switch: Locations Ignition Switch Page 3047 Steps 10-13 Page 1401 Chassis Harness, Fuel Tank Page 13983 Steps 7-12 Page 8347 Auxiliary Blower Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 12793 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 423 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 912 6. Install the rear electrical center cover. 7. If replacing the body wiring harness extension on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 8. If replacing the body wiring harness extension on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 9. Connect the negative battery cable. Page 6309 Brake Rotor/Disc: Service and Repair Disc Brake Splash Shield Replacement - Front Disc Brake Splash Shield Replacement- Front Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the front hub and bearing assembly. 4. Remove the retaining bolts for the splash shield. 5. Remove the splash shield. Installation Procedure 1. Install the splash shield. 2. Install the splash shield retaining bolts, same as wheel hub and bearing. 3. Install the front hub and bearing assembly. 4. Install the tire and wheel assembly. 5. Lower the vehicle. Page 12720 sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 10633 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 8157 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 2906 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 3920 Abbreviations And Meanings Part 7 Page 12366 Memory Seat Module - Passenger C4 Part 2 Page 12885 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 13078 Steering Wheel Controls Page 3932 Abbreviations And Meanings Part 19 Page 14001 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 6574 OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 4656 Steps 10-13 Page 9687 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 1881 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator support diagonal brace if applicable. 2. Remove the radiator air intake baffle if applicable. 3. Loosen the three air cleaner cover/resonator retaining screws (2) one shown, and remove the cover/resonator (1). 4. Lift the air cleaner element (1) and air outlet duct (3) from the lower air cleaner housing/washer solvent tank assembly (2). 5. Remove the air cleaner element (1) by grasping the air cleaner element and removing it from the air outlet duct (3) with a twisting and pulling motion. 6. Inspect the entire assembly for debris or damage and repair as necessary. INSTALLATION PROCEDURE Page 13405 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Diagram Information and Instructions Information Bus: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 6810 Abbreviations And Meanings Part 14 Page 4229 Page 13136 Abbreviations And Meanings Part 8 Locations Electronic Components Page 10756 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 12128 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Description and Operation Coolant Reservoir: Description and Operation Coolant Recovery System The coolant recovery system consists of a plastic coolant recovery reservoir and overflow tube. The recovery reservoir is also called a recovery tank or expansion tank. This reservoir is partially filled with coolant and is connected to the radiator fill neck with the overflow tube. Coolant can flow back and forth between the radiator and the reservoir. In effect, a cooling system with a coolant recovery reservoir is a closed system. When the pressure in the cooling system gets too high, the pressure valve opens in the pressure cap. This allows the coolant, which has expanded due to being heated is allowed to flow through the overflow tube and into the recovery reservoir. As the engine cools down, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum opens the vacuum valve in the pressure cap, allowing some of the coolant in the reservoir to be siphoned back into the radiator. Under normal operating conditions, coolant is not lost. Although the coolant level in the recovery reservoir goes up and down, the radiator and cooling system are kept full. An advantage to using a coolant recovery reservoir is that most of the air bubbles are eliminated from the cooling system. Coolant without bubbles absorbs heat much better than coolant with bubbles. Page 6907 Abbreviations And Meanings Part 22 Page 7282 Abbreviations And Meanings Part 18 Page 7844 11. Remove lower ball joint retaining nut. 12. Disconnect lower ball joint from steering knuckle using J43631. Important: Take care not to disengage the axle shaft from the transmission (4WD Only). 13. Pivot the the lower control arm outward and downward in order to disconnect the lower control arm from the lower control arm bracket. 14. Remove the lower control arm from the steering knuckle. Installation Procedure 1. Install the lower control arm to the steering knuckle. Important: Take care not to disengage the axle shaft from the transmission. 2. Pivot the the lower control arm outward and upward in order to connect the lower control arm to the lower control arm bracket. 3. Install the lower control arm to the lower control arm bracket. Page 7353 Fuse Block - Underhood C2 Part 4 Page 11975 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 10318 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Description and Operation Air Bag Harness: Description and Operation INFLATABLE RESTRAINT WIRING HARNESS The inflatable restraint wiring harnesses connect the inflators modules, SDM, deployment loops, and class 2 serial data together using weather pack connectors. SIR system connectors are yellow in color for easy identification. When repairing the SIR wiring harnesses follow the proper testing and wiring repair procedures listed in this manual. Page 7223 Page 12833 Abbreviations And Meanings Part 10 Page 13533 Door Switch: Diagrams Miniwedge (Door Jamb Switch) - LF Page 11883 Door Lock Actuator - Front Passenger Page 6452 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the two electrical harness connectors from the EBCM (2). Important: Make sure that brake lines are tagged and kept in order for proper reassembly. 2. Disconnect the 5 brake lines from the BPMV (3). 3. Remove 2 bolts (4) securing the BPMV mounting bracket (5) to the BPMV (3). 4. Disconnect the 2 way ABS pump motor connector. 5. Remove the four T-25 TORX screws (1) from the EBCM (2). Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 7. Clean the EBCM (2) to BPMV (3) mounting surfaces with a clean cloth. Installation Procedure Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Page 14002 Page 2014 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Remove the oil fill cap. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the oil pan drain plug and drain the oil into a suitable container. Important: 0mCheck the old oil filter to ensure the filter seal is not left on the engine block. 4. Remove the oil filter using a suitable wrench. 5. Wipe the excess oil from the oil filter housing. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. NOTICE: Refer to Fastener Notice in Service Precautions. See: Engine, Cooling and Exhaust/Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the new oil filter. Tighten the oil filter to 17 Nm (22 ft. lbs.) plus 150°. 3. Install the oil pan drain plug. Tighten the oil pan drain plug to 26 Nm (19 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. Page 5466 Seals and Gaskets: Service and Repair Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the Park/Neutral Position (PNP) Switch. 3. Be sure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 4. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 5. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. 4. Install the PNP Switch. 5. Lower the vehicle. 6. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Page 12114 Page 13199 Page 2912 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 660 Memory Seat Module - Driver C3 Part 1 Memory Seat Module - Driver C3 Part 2 Page 10438 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 10904 Body Control Module (BCM) C3 Part 2 Page 11420 Tighten the screw to 5 N.m (44 lb in). 8. Remove the window bracket to the window frame pin (1). 9. Verify the operation of the body side window. 10. Install the rear interior trim panel. Page 6676 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 10576 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Accessory Delay Module DIAGNOSTIC STARTING POINT - ACCESSORY DELAY MODULE Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The Diagnostic System Check will provide the following information: - Class 2 communication status - "U" codes which indicate module communication or circuit failure - "B" codes which indicate a possible body function or circuit failure - The status of any "U" or "B" codes Diagnostic System Check - Accessory Delay Module DIAGNOSTIC SYSTEM CHECK - ACCESSORY POWER MODULE TEST DESCRIPTION Steps 1-3 A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Page 8092 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 12552 Abbreviations And Meanings Part 20 A/T - Shift Lock Control Actuator Available Shift Interlock Solenoid: Technical Service Bulletins A/T - Shift Lock Control Actuator Available Bulletin No.: 05-07-129-001B Date: February 16, 2007 INFORMATION Subject: Automatic Transmission Shift Lock Control Actuator Available for Service Use Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2006 Chevrolet TrailBlazer EXT 2003-2006 Chevrolet SSR 2002-2007 GMC Envoy 2002-2006 GMC Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add the SSR. Please discard Corporate Bulletin Number 05-07-129-001A (Section 07 - Transmission/Transaxle). The automatic transmission shift lock control actuator is now available for service as a separate part. The actuator was formerly available only as part of the entire shifter assembly. DO NOT replace the shifter assembly if the shift lock control actuator requires replacement. Please refer to the Automatic Transmission Shift Lock Control Actuator Replacement procedure in the Automatic Transmission sub-section of the Service Information. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 11391 Optimal results will be obtained by allowing the seal to remain in a compressed state with the glass closed for a period of 48 hours. Parts Information Parts are expected to be available from GMSPO on June 13, 2003. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Page 6879 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 4917 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 2515 1. Lubricate and fill the valve lash adjusters with engine oil. 2. Install the valve lash adjusters in their original locations. 3. Lubricate the valve rocker arm roller. 4. Install the valve rocker arms in their original locations. 5. Coat the camshaft journals with engine oil. 6. Install the camshafts to their original position Page 896 Body Control Module (BCM) C3 Part 3 Page 10343 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 96 Steps 1-6 Page 3676 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). 4. Lower the vehicle. Page 12983 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 480 Parts Information Page 4967 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Slde Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Only if necessary remove the fuel tank shield. IMPORTANT: Due to an access hole in the fuel tank shield, removal of the shield should not be necessary to access the fuel pressure service connection. 3. Remove the fuel pressure service connection cap, located near the fuel filter. 4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Turn ON the ignition. 6. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 8. Command the fuel pump ON with a scan tool. 9. Close the bleed valve on the fuel pressure gage. 10. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. Page 9538 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 13118 Various symbols in order to describe different service operations. Page 13552 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition contained in this bulletin are to be submitted by August 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle Page 6799 Abbreviations And Meanings Part 3 Page 12452 1. Install the rear seat cushion bracket to the seat cushion bottom with the four mounting nuts (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat cushion bracket mounting nuts to 25 N.m (18 lb ft). 2. Install the rear seat bracket trim covers (1). 3. Install the seat in the vehicle. Seat Cushion Latch Release Assembly Replacement - Rear No. 1 SEAT CUSHION LATCH RELEASE ASSEMBLY REPLACEMENT - REAR NO. 1 (TRAILBLAZER, ENVOY, BRAVADA) REMOVAL PROCEDURE 1. Remove the rear seat cushion assembly from the vehicle. 2. Remove the rear-seat cushion cover and the pad. 3. Remove the strap (1) from the rear seat cushion latch (2). Page 10003 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Page 9155 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 9029 6. Install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten Tighten the rear seat belt upper guide bolt to 70 N.m (52 lb ft). Page 2829 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 1623 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 9451 Disclaimer Page 13258 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 5394 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Page 10567 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 4658 Steps 16-19 Page 7469 C201 Part 2 Page 12227 Memory Seat Module - Driver C3 Part 1 Memory Seat Module - Driver C3 Part 2 Page 9148 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Instruments - Erratic Speedometer Operation Engine Control Module: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 420 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Locations Instrument Harness, Instrument Panel Page 12423 6. Remove the seat back cushion mounting bolts (2) securing the rear seat back frame to the inboard/outboard rear seat back cushion hinge assembly. INSTALLATION PROCEDURE 1. Install the seat back cushion mounting bolts (2) securing the rear seat back frame to the inboard/outboard rear seat back cushion hinge assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten all rear seat back cushion mounting bolts to 25 N.m (18 lb ft). 2. Install the rear center seat belt retractor assembly, if you are replacing the frame from the left-hand rear seat. Ignition System - MIL ON/Misfire DTC's In Wet Weather Cowl Moulding / Trim: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 9809 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 13891 Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front .................................................................................................................................................... .......................................................... 0.8L (2.6 Pints) Rear ................................................................ ............................................................................................................................................... 1.9L (4.0 Pints) Rear with 8.6" Ring Gear ................................................................................................... ........................................................................... 2.2L (4.8 Pints) Page 3358 4. Install the lower radiator support shield, if equipped. 5. Lower the vehicle. 6. Install the inlet radiator hose to the thermostat (1). 7. Reposition the inlet radiator hose using J 38185. 8. Fill the cooling system. Page 6481 6. Adjust the park brake shoe (1). 7. Install the rear brake rotor. 8. Install the rear park brake cable to the park brake actuator lever. Page 7540 9. Install the 3 bolts (1) that retain the junction block to the block base. Tighten Tighten the 3 bolts to 3.5 N.m (31 lb in). 10. Install the BCM to the rear electrical center. 11. Install the battery feed terminal nut (2) to the junction block. Tighten Tighten the battery feed terminal nut to 10 N.m (88 lb in). 12. Install the rear electrical center cover. 13. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a passenger position. 14. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 15. Connect the battery negative cable. Page 6806 Abbreviations And Meanings Part 10 Page 9426 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 4338 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 10660 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 5253 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 8280 Ambient Temperature Sensor / Switch HVAC: Diagrams Air Temperature Sensor-Lower Left Page 12035 WA8624/50 - WA8624/50 Page 10365 Abbreviations And Meanings Part 18 Page 9614 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 3175 32. Install the new hose (1), # 1005 (L6 engine) or# 1006 (V8 engine) onto the coolant bypass valve at the location the above hose was removed. The other end of this hose will be installed on the auxiliary heater pump outlet port. Locations Door Switch: Locations Door Jamb Switch, Miniwedge - LR Page 11620 lowered to the correct height so that notches on each tumbler are at the same level. When the notches on all 6 tumblers line up, 2 small springs push the side bar into the notches, allowing the cylinder to turn in the cylinder bore. Five types of tumblers are used in making the lock combinations, and each is coded and stamped with a number between 1 and 5. ASSEMBLING AND CODING IGNITION LOCK CYLINDERS TOOLS REQUIRED J 41340 Ignition Lock Holding Fixture 1. Determine the tumbler numbers/arrangement: 1.1. Place the tip of the key directly over the tip of the illustrated key. 1.2. Inspect that the diagram outlines the key. 1.3. Starting with position 1 (open end of cylinder), find and record the lowest level (tumbler number) that is visible. 1.4. Repeat the previous step for positions 2-10. 2. Starting with position 1, insert the tumblers (4) into their corresponding slots in the coded order. 3. Using your fingers, pull out the side bar (3) until the tumblers fall completely into place. 4. Insert one tumbler spring (2) above each tumbler (4). 5. Lubricate the tumblers using Superlube(r) GM P/N 12346241 or equivalent. 6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder. Page 3048 Steps 14-15 Page 1054 Page 11860 Mirror Connector, Front Passenger Door Module (FPDM) - C3 Part 2 Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 11763 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 6174 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 10108 Disclaimer Page 12651 1. Position the memory seat switch to the lock and door lock and side window switch (1). 2. Connect the electrical connector (2) to the memory seat switch. 3. Install the door lock and side window switch (1). Verify that the front retaining clips and the rear retaining clips are fully seated. A/C - Musty Odors On Start Up Evaporator Core: Customer Interest A/C - Musty Odors On Start Up Bulletin No.: 05-01-39-002A Date: March 17, 2006 TECHNICAL Subject: Musty Odor from HVAC System (Reprogram HVAC Control Module to Enable Afterblow Function) Models: 2004-2006 Buick Rainier 2003-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2003-2004 Oldsmobile Bravada with Automatic Temperature Control HVAC System (RPO CJ2) Supercede: This bulletin is being revised to add the 2006 model year and update the calibration release date. Please discard Corporate Bulletin Number 05-01-39-002 (Section 01 - HVAC). Condition Some customers may comment on a musty odor from the Heating, Ventilation and Air Conditioning (HVAC) system. This condition occurs most often on initial start up after the vehicle was driven on a hot humid day. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. Correction Important: The afterblow function should not be enabled until after the purpose and operation of it is explained to your customer and they approve of the change. Once the afterblow function is enabled there are no calibrations currently released to disable it. Technicians are to reprogram the HVAC Control Module with an updated software calibration that will enable the afterblow function. The new calibration will be released beginning with TIS satellite data update version 2.0, which was made available February 5, 2006. The blower motor will turn on approximately 10 minutes after the vehicle is shut off. The blower motor will run continuously for 10 minutes at a 30% duty cycle. The afterblow function will only activate if the air conditioning compressor was engaged during conditions of high ambient temperature. If the vehicle is started within 10 minutes of the last key off, the afterblow function from the previous key cycle will be cancelled. Technicians should not attempt to reprogram a vehicle with a Manual Temperature Control HVAC system (RPO CJ3). Technicians should perform this HVAC Control Module reprogram instead of installing the Electronic Evaporator Dryer Module Kit referred to in the Air Conditioning Odor bulletin, Corporate Bulletin Number 99-01-39-004A. Warranty Information Page 10852 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 7528 Application Table Part 2 Page 13268 Abbreviations And Meanings Part 6 Page 6438 Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 13019 Abbreviations And Meanings Part 20 Page 8645 1. Install new O-ring seals. 2. Install the compressor discharge hose (2) to the condenser (4). 3. Install the compressor discharge hose nut. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the hose nut to .....28 N.m (21 lb ft). 4. Install the compressor hose to the connector through the driver wheel opening. 5. Install the nut. Tighten Tighten the nut to .....48 N.m (35 lb ft). 6. Install the compressor suction hose to the stud on the engine. 7. Install the nut. Tighten Tighten the nut to .....48 N.m (35 lb ft). 8. Install the compressor suction hose to the engine lift bracket. 9. Install the bolt. Tighten Tighten the bolt to .....48 N.m (35 lb ft). 10. Connect the compressor suction hose (1) to the accumulator. 11. Install the compressor suction hose nut to the accumulator. Tighten Tighten the nut to .....48 N.m (35 lb ft). 12. Install the sealing washers. Locations Upper Console Page 10520 Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 13982 Steps 1-6 Page 7178 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 5397 Disclaimer Specifications Engine Oil Pressure: Specifications Oil Pressure (At the sending unit) Warm - Minimum 12 psi - 1200 RPM Locations Engine, Left Side Page 12374 Seat Lumbar Motors And Position Sensors Assembly - Driver Part 1 Page 12954 Locations Park Neutral Position (PNP) Switch Page 1519 29. Install the auxiliary heater pump and bracket onto the dash panel studs. 30. Reinstall the HVAC plate and nuts. 31. On the coolant bypass valve, remove the hose (1) that went from the valve to the engine and discard. Page 6191 Various symbols in order to describe different service operations. Page 11716 1. Remove the cargo shade/cover. 2. Remove the left body side upper trim panel. 3. Remove the liftgate sill plate. 4. Remove the left rear door sill panel. 5. Remove the lower seat belt anchor bolt. 6. Release the clips that retain the trim panel to the body. 7. Remove the trim panel from the vehicle. INSTALLATION PROCEDURE 1. Position the trim panel to the vehicle. 2. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 3. Index the locating tabs on the trim panel to the holes in the body. 4. Seat the clips the retain the trim panel to the body. 5. Install the seat belt lower anchor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the anchor bolt to 70. N.m (52 lb ft). 6. Install the left rear door sill panel. 7. Install the liftgate sill plate. 8. Install the left body side upper trim panel. Trim Panel Replacement - Rear Quarter - Left - 2 TRIM PANEL REPLACEMENT - REAR QUARTER - LEFT (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE Page 4459 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolt Torque Sequence Exhaust Manifold Bolts First pass ............................................................................................................................................. ................................................. 20 Nm (15 ft. lbs.) Second pass ........................................................ ................................................................................................................................ 20 Nm (15 ft. lbs.) Final pass ............................................................................................................................................ ................................................ 20 Nm (15 ft. lbs.) Page 12931 Abbreviations And Meanings Part 20 Testing and Inspection Oil Level Warning Indicator: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 2993 Engine Oil Level And Temperature Sensor Page 6971 Fuse Block - Underhood C2 Part 1 Page 798 6. Connect the mobile telephone harness connector (1) to the junction block. 7. Connect the instrument panel harness connector (1) to the block base. 8. Install the junction block to the block base. Ensure that the retaining tabs are fully seated. Engine - New Cylinder Bore Sleeve Replacement Procedure Cylinder Liner: Technical Service Bulletins Engine - New Cylinder Bore Sleeve Replacement Procedure Bulletin No.: 04-06-01-022B Date: October 24, 2005 SERVICE MANUAL UPDATE Subject: New Cylinder Bore Piston Sleeve Replacement Procedure Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer 2004-2006 Chevrolet Colorado 2002-2006 GMC Envoy 2004-2006 GMC Canyon 2002-2004 Oldsmobile Bravada with 2.8L, 3.5L or 4.2L Engine (VINs 8, 6, S - RPOs LK5, L52, LL8) Supercede: This bulletin is being revised to update model years, bulletin content, add parts information and the tool part number in the Warranty information and the Cylinder Sleeve Trimming/Trim Tool Cutter information. Please discard Corporate Bulletin Number 04-06-01-022A (Section 06 Engine/Propulsion System). A new procedure has been developed to replace the cylinder bore sleeves in the 2.8L, 3.5L and 4.2L engines. This procedure has been added to the Service Manual in the Engine Mechanical sub-section. This procedure may be used when the engine is in or out of the vehicle. Cylinder Bore Sleeve Removal Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. Note: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur. 1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore. Page 599 Abbreviations And Meanings Part 11 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Page 9006 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 4. Install the LF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Page 6989 Application Table Part 3 Location View Page 62 Abbreviations And Meanings Part 7 Service and Repair Radiator Cooling Fan Motor Relay: Service and Repair Cooling Fan Relay Replacement Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the underhood electrical center cover. 2. Using the J 43244, remove the cooling fan relay (3). Installation Procedure NOTICE: Installation of the proper relay is critical. If an enhanced relay equipped with a diode is installed into a position requiring a standard relay equipped without a diode; excessive current will damage any components associated with the relay or its associated circuits. 1. Install the cooling fan relay (3). 2. Install the underhood electrical center cover. Page 6015 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Slde Page 9536 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 12962 Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Only if necessary remove the fuel tank shield. IMPORTANT: Due to an access hole in the fuel tank shield, removal of the shield should not be necessary to access the fuel pressure service connection. 3. Remove the fuel pressure service connection cap, located near the fuel filter. 4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Turn ON the ignition. 6. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 8. Command the fuel pump ON with a scan tool. 9. Close the bleed valve on the fuel pressure gage. 10. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. Page 11621 7. Press down the retainer (1) until fully seated in the depression. 8. Inspect for proper tumbler installation: 8.1. Hold the spring retainer (2) in position. 8.2. Insert the key (1) into the cylinder. 8.3. The side bar (3) should drop down flush with the cylinder diameter if properly installed. 8.4. Disassemble and assemble properly as needed. 9. Remove the key. Page 1293 Miniwedge (Door Jamb Switch) - RR Page 2903 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 3081 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic converter. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Page 7248 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 500 4. Install the protective cover to the module. 5. Position the right rear seat bottom to a passenger position. 6. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 7. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 8. Use the ID information menu on the scan tool to access the new station ID (STID) and the electronic serial number (ESN) from the new VCIM. 9. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center and perform the following procedure: 9.1. Tell the advisor that this vehicle has received a new VCIM. 9.2. Ask the advisor to add the new STID and the ESN to update the customer's account. 9.3. Follow any additional instructions from the OnStar(R) advisor. 9.4. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Page 11619 Console Storage Bin Replacement Removal Procedure 1. Open the storage bin cover. 2. Remove the 6 screws that retain the storage bin to the console. 3. Remove the storage bin from the console. Installation Procedure 1. Install the storage bin to the console. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 6 screws that retain the storage bin to the console. Tighten the screws to 2.5 N.m (22 lb in). 3. Close the storage bin cover. Key and Lock Cylinder Coding KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE The lock cylinder keyway is designed so that other model keys will not enter a current model lock cylinder. A single key is used for all locks on the vehicle. The key identification is obtained from the four-character key code stamped on the knockout portion of the key head. Knock the plugs out of the key head after code numbers have been recorded. The code list, available to owners of key cutting equipment from equipment suppliers, determines the lock combinations from the code numbers. CUTTING KEYS After the code has been determined from the code list or the key code diagram, perform the following steps: 1. Cut a blank key to the proper level of each of the tumbler positions. 2. Inspect the key operation in the lock cylinder. REPLACEMENT LOCK CYLINDERS New lock cylinders (except ignition lock cylinders) are available from the service parts warehouse with new lock cylinder locking bars. The tumblers are also available and must be assembled into the cylinder as recommended. For additional information, refer to the following. LOCK CYLINDER TUMBLER OPERATION All lock tumblers are shaped alike with the exception of the notched position on one side. As the key is inserted into the lock cylinder, the tumblers are Page 124 Page 12078 WA900J/59 - WA9260/74 Page 2532 Crankshaft Main Bearing: Specifications Crankshaft Main Bearing Cap Bolt First Pass 18 ft. lbs. Final Pass 180 degrees Crankshaft Position Sensor Bolt 89 inch lbs. Crankshaft Rear Housing Bolt 89 inch lbs. Crankshaft Main Journal Diameter 2.7567-2.7574 inch Main Journal Taper - Maximum 0.0002 inch Out Of Round - Maximum 0.0002 inch Cylinder Block Main Bearing Bore Diameter 3.0760-3.0766 inch Crankshaft Main Bearing Inside Diameter 2.7579-2.7592 inch Main Bearing Clearance 0.0004-0.0025 inch Crankshaft End Play 0.0044-0.0153 inch Page 11344 Endgate Module (EGM) C2 (XUV) Part 2 A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 149 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 9326 Page 3533 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). 7. Disconnect the 40-way body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. Locations Front Passenger Seat Page 12531 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 12837 Abbreviations And Meanings Part 14 Page 12465 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 4 nuts that secure the seat pan to the power seat adjuster frame. Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 5. Install the seat harness to the seat pan. 6. Install the SIR harness (2) to the seat clips (1, 4). 7. Connect the gray lumbar electrical connector (5), if equipped. 8. Connect the black electrical connector (3) to the seat belt buckle. 9. Connect the black electrical connector (6) to the seat back harness. 10. Install the 3 seat switch bezel mounting screws. Seat Cushion Outer Trim Panel Replacement Seat Cushion Outer Trim Panel Replacement Removal Procedure 1. Remove the trim panel from the power seat by performing the following: 1. Remove the 3 seat switch bezel mounting screws. 2. Remove the 3 trim panel retaining screws. 2. Remove the trim panel from the manual seat by performing the following steps: 1. Remove the lumbar support knob. 2. Remove the seat back recliner handle. 3. Remove the screws from the trim panel. 3. Remove the trim panel from the seat assembly. Installation Procedure Powertrain Control Module (PCM) C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Powertrain Control Module (PCM) C1 Part 1 Locations Engine, Left Side Page 9674 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 2680 8. Install the engine protection shield and secure the shield with the bolts. Tighten the engine protection shield bolts to 25 Nm (18 ft. lbs.). 9. Install the right and the left lower engine mount nuts. Torque the lower engine mount nuts to 70 Nm (52 ft. lbs.). 10. Lower the vehicle. 11. Install the left shock module. 12. Install the MAP sensor (2). 13. Install the MAP sensor retainer (1) and the electrical connector. Page 9967 Page 421 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 3884 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 12555 Abbreviations And Meanings Part 23 Page 4294 Registered And Non-Registered Trademarks Part 2 Page 7243 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 7987 7. Install the shock module yoke to the shock absorber. 8. Install the shock module yoke to shock absorber pinch bolt and nut. Tighten the shock module yoke to shock absorber pinch bolt to 70 Nm (52 ft. lbs.). 9. Install the shock module to the vehicle. 10. Install the tire and wheel. 11. Lower the vehicle. Shock Module Yoke Replacement Shock Module Yoke Replacement Tools Required ^ J24319-B Steering Linkage and Tie Rod Puller Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the shock module yoke to lower control arm mounting nut. Specifications Oil Level Sensor: Specifications Oil Level Sensor Bolt 89 inch lbs. Page 10623 Page 5731 Page 11291 2. Position the latch to the previously marked location on the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts which retain the latch to the mounting bracket. Tighten the bolts to 10 N.m (89 lb ft). 4. Inspect the latch for proper operation before closing the hood. 5. Check the alignment of the latch to the hood striker. Adjust the latch if necessary. Refer to Hood Latch Adjustment. 6. Install the grille. Page 5531 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Diagrams Trunk / Liftgate Switch: Diagrams Liftgate Ajar Switch Page 10195 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 6162 Page 13535 Miniwedge (Door Jamb Switch) - LR Page 6956 Fuse Block - Rear C2 Part 4 Page 12544 Abbreviations And Meanings Part 12 Page 201 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 11401 1. Position the latch/lock assembly to the liftgate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the latch/lock assembly to the liftgate. Tighten the screws to 10 N.m (89 lb in). 3. Connect the lock cylinder bellcrank rod (1) to the latch/lock assembly. 4. Connect the electrical connector to the latch/lock assembly. 5. Position the bellcrank to the latch/lock assembly. 6. Install the screws that retain the bellcrank to the latch/lock assembly. Tighten the screws to 0.7 N.m (6 lb in). 7. Connect the bellcrank rod to the latch/lock assembly. 8. Connect the outside handle rod to the bellcrank. 9. Install the liftgate trim panel. 10. Install the liftgate window garnish molding. Page 9427 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 9369 Abbreviations And Meanings Part 3 Page 13959 Registered And Non-Registered Trademarks Part 3 Page 3180 40.6. Install the ring terminal (orange wire) to the underhood fuse block stud (1). 40.7. Locate circuit no. 241 or 441 (ignition 3 brown wire) (PIN B11 or C11) in the existing underhood fuse block harness (1) of C2 (2) and splice bare wire to it using a splice clip. Wrap with electrical tape. 40.8. Locate connector C105 (3), located on the left side inner fender. Separate the connector halves. On the female side of the connector, remove the terminal from cavity F (gray/black wire) and tape back. 40.9. Install the terminal end on the pump wiring harness into cavity F of connector C105. 41. Install the evaporator tube and nut to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 42. Install the coolant recovery reservoir with the accumulator attached. 43. Install the nut and bolt securing the coolant recovery reservoir. 44. Install the coolant hoses to the coolant recovery reservoir. 45. Install the nut retaining the accumulator to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 46. Install the compressor suction hose assembly to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). Page 10868 Abbreviations And Meanings Part 4 Page 13566 this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT RECALL CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the Claim Form provided to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. All recall reimbursement questions should be directed to the following number: 1-800-204-0261. Disclaimer Service Procedure Page 146 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 7139 7. Remove the junction block bracket retaining bolts (1) and remove the junction block bracket from the vehicle. INSTALLATION PROCEDURE 1. Position the junction block bracket and install the bolts (1). Tighten Tighten the junction block bracket bolts to 6 N.m (53 lb in). 2. Align the wiring harnesses and install the fuse relay center. 3. Install the fuse relay center bolts (3). Tighten Tighten the relay center bolts to 6 N.m (53 lb in). Page 10836 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 10385 Steps 4-6 The numbers below refer to the step numbers on the diagnostic table. 1. This step verifies that the RAP power mode function is malfunctioning by checking functions internally enabled by the BCM. 4. The BCM sends Class 2 messages to other control modules via the serial data link, allowing them to operate in RAP power mode. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 5. This step is checking for DTCs in the BCM. 6. The presence of DTCs which begin with "U" indicate that other module is not communicating. The specified procedure will compile all the available information before tests are performed. Page 12324 3. Remove the retaining clip from each head restraint post. 4. Remove the head restraint from the seat back. INSTALLATION PROCEDURE 1. Install the retaining clips to the head restraint retractor. 2. Verify that the retaining clips are fully seated. 3. Install the rear seat head restraint posts to the head restraint retractor, verifying that the notches in the head restraint posts are indexed toward the back of the seat. 4. Lower the head restraint to the full down position. Head Restraint Guide Replacement - Rear No. 1 HEAD RESTRAINT GUIDE REPLACEMENT - REAR NO. 1 REMOVAL PROCEDURE 1. Remove the head restraint. 2. Remove the seat back cover and pad high enough to expose the head restraint guides. Page 11211 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. For 2007 vehicles repaired under warranty, use the table. Disclaimer Page 6464 5. Remove the master cylinder from the vehicle. 6. Drain the master cylinder reservoir of all the brake fluid. 7. Remove the reservoir from the master cylinder, if needed. Installation Procedure 1. Install the reservoir on the master cylinder, if needed. Page 1889 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic converter. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Locations Body Front End Page 9132 Page 9192 Abbreviations And Meanings Part 25 Page 14014 Page 5772 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12364 Memory Seat Module - Passenger C3 Part 2 Page 89 Accessory Delay Module: Electrical Diagrams Retained Accessory Power (RAP) Diagram Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Press tabs (1) inward and lift to remove the junction block cover. 3. Pull upward on the fuse relay center cover (1) to release the retaining tabs and remove the cover. 4. Note the location and remove the harness end bolts (2) and remove the harness ends from the fuse relay center. 5. Remove the fuse relay center bolts (3) and remove the fuse relay center from the junction block bracket. 6. Pull downward on the wiring harness ends to remove from the bottom of the fuse relay center. Page 5842 8. Install the J8614-01 as shown. 9. Remove the pinion nut while holding the J8614-01. 10. Remove the washer. 11. Install the J8614-3 (2) and the J8614-2 (3) into the J8614-01 (1) as shown. 12. Remove the pinion yoke by turning the J8614-3 (3) clockwise while holding the J8614-01 (1). Use a container in order to retrieve the lubricant. 13. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J33782, 8.0 inch axle or the J38694 8.6 inch axle. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. Page 11140 9.1. Replace the latch assembly. 9.2. Proceed to Step 11. 10. If two distinct audible clicks are heard: 10.1. Ensure that the fork bolt is in the fully latched position. 10.2. Blow out the latch in the area of the detent with compressed air. 11. Lubricate both sides of the detent pivot by spraying with GM Superlube for one second, and then cycle the latch open and closed several times to work the lubrication into the pivot. 12. Repeat Steps 1 through 11 for the rear door on the other side. Page 6903 Abbreviations And Meanings Part 18 Page 7802 5. With the applicator hose down as far as possible toward the mating area of the serrations, spray a generous amount of grease. 6. Repeat the application after rotating the steering wheel 180 degrees, so that the serrations are treated in two locations opposite each other. 7. Position the floor air outlet duct into place and install the push pin retainer. 8. Raise the insulator panel and install the retaining clip to the IP substrate. 9. Install the two screws that retain the left closeout/insulator panel to the IP. Use the following steps to remove material from the upper intermediate shaft bushing. 1. Push the upper intermediate shaft boot seal (2) down toward the floor in order to completely expose the white bushing (1). 2. Using fine or very fine sandpaper, remove material from the intermediate shaft bushing. Sand around the entire face of the bushing sufficient enough to obtain clearance and reduce the drag between the intermediate shaft bushing and the upper boot seal. 3. Return the upper intermediate shaft boot seal to its original position. 4. Clean debris as necessary. Parts Information Warranty Information Page 244 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 1823 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Page 12719 outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the Page 1451 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 2936 Abbreviations And Meanings Part 8 Page 9339 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 837 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 6819 Abbreviations And Meanings Part 23 Page 9319 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 1729 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 8584 For vehicles repaired under warranty, use the table. Disclaimer Page 335 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 12989 Various symbols in order to describe different service operations. Page 11859 Mirror Connector, Front Passenger Door Module (FPDM) - C3 Part 1 Page 10155 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Page 12238 Memory Seat Module - Passenger C4 Part 3 Page 411 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 6858 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 5506 10. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Page 10491 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 1672 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 4160 Steps 10-12 Page 6976 Fuse Block - Underhood C2 Part 6 Fuse Block - Underhood C3 Part 1 Page 6211 Abbreviations And Meanings Part 10 Page 13000 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 7985 7. Install pieces of heater hose to the shock module spring where J45400 contacts lower part of spring. 8. Install the shock module (2) into the J45400 (1). Important: The spring is compressed when the shock absorber moves freely. 9. Turn the spring compressor forcing screw (1) until the coil spring (2) is compressed. 10. Remove the shock absorber upper retaining nut. 11. Remove the shock absorber from the shock module. 12. Loosen the compressor forcing screw until the upper mounting plate and coil spring may be removed. 13. Remove the upper mounting plate and coil spring from the J45400. Installation Procedure 1. Install the coil spring and upper mounting plate to the J45400. Page 6295 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Page 3288 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Page 583 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Weatherstrip Replacement - Auxiliary Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Page 3585 Powertrain Control Module (PCM) C2 Part 6 Page 5452 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Air Suspension Sensor - LR Page 11015 Disclaimer Page 10359 Abbreviations And Meanings Part 12 Page 2854 During the 2004 model year, there was a design change made to the engine oil pick up tube and the front cover as shown. The first design parts used in production for 2002, 2003 and part of 2004 model year used an 0-ring type seal between the pick up tube and the front cover. The second design parts began production during the 2004 model year and use a face type seal. Anytime the front cover or oil pick up tube are being serviced, be sure to identify which design is being serviced. The correct pick up tube must be used with its corresponding front cover or an engine failure could result. Any vehicle requiring a new front cover must be serviced with the second design front cover, therefore, the engine oil pick up tube must be replaced at the same time. Disclaimer Page 9008 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 4. Install the RF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 3. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. Page 9185 Abbreviations And Meanings Part 18 Page 1111 Position Sensor - Rear Motor (w/Memory) Specifications Camshaft Housing: Specifications Camshaft Cover Bolt 89 inch lbs. Page 2186 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Recall 05V494000: Rear Door Latch Corrosion Rear Door Latch: All Technical Service Bulletins Recall 05V494000: Rear Door Latch Corrosion MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Trailblazer EXT 2002-2003 GMC/Envoy XL 2002-2003 Isuzu/Ascender 2003 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V494000 MFG'S REPORT DATE: October 26, 2005 COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 98007 SUMMARY: Certain sport utility vehicles have a rear side closure latch that may not latch or unlatch due to corrosion caused by road splash, such as water and road salt. These vehicles are registered or sold in the following states: Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and The District of Columbia. CONSEQUENCE: If the door is not latched properly and it goes unnoticed, it may open while the vehicle is in motion. If an occupant fell out of the vehicle, personal injuries could occur. REMEDY: Dealers will install a seal along the lower part of the rocker panel to prevent intrusion of corrosive material, and inspect the rear side closure latches. Functional latches will be cleaned and lubricated. Non-functioning latches will be replaced. The recall is expected to begin during January 2006. Owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or Isuzu at 1-800-255-6727. NOTES: GM recall No. 05077. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 7084 C105 Part 2 Page 3858 Intake Air Temperature (IAT) Sensor Page 11040 Front Door Hinge: Service and Repair Hinge Replacement - Front Door - Body Side Hinge Replacement - Front Door - Body Side Removal Procedure The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all hinges. 1. Remove all of the related panels and components. 2. Remove the sealer surrounding the hinge (1). 3. Scribe the location of the hinge (1). 4. Hand-sand the existing hinge (1) with 100 grit sandpaper to locate the 4 weld locations. Page 7492 C313 Page 910 10. With an upward motion, disconnect the body wiring extension (1) from the rear electrical center. 11. Remove the body wiring extension from the vehicle. INSTALLATION PROCEDURE 1. Using a downward motion, install the body wiring extension (1) to the rear electrical center. IMPORTANT: Ensure the sliding latch is fully extended before connecting the body wiring extension to the rear electrical center. Page 2252 Application Table Part 3 Location View Page 13718 Miniwedge (Door Jamb Switch) - RR Page 6607 Do NOT attach the positive jumper cable to the stud located under the engine compartment fuse block cover. Doing so may blow the fuse resulting in various interior electrical system conditions. Disclaimer Page 10270 Steering Wheel Controls Page 2842 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield. 3. Remove the electrical connector from the oil pressure switch. 4. Remove the oil pressure switch. Installation Procedure NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the oil pressure switch. Tighten the oil pressure switch to 20 Nm (15 ft. lbs.). 2. Install the electrical connector to the oil pressure switch. 3. Install the engine shield. 4. Lower the vehicle. Page 1415 Knock Sensor (KS) 2 Front Page 7483 C307 Part 1 Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Read this procedure carefully and completely. 2. The BCM will not function properly if the Setup New BCM procedure is not performed. 3. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 11640 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the EFS connectors to both (2) EFS's. 3. Install the CPAs to both EFS connectors. 4. Install sensor bracket to bumper. 5. Install the grille. 6. Install the SIR fuse into the fuse block (1) located in the underhood fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 1. Remove the key from the ignition. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. The scan tool instructs you to perform the following items: - Accelerate to wide open throttle (WOT). - Release the throttle when fuel cut-off occurs. - Observe the fuel cut-off for the engine that you are performing the learn procedure on. - The engine should not accelerate beyond calibrated RPM value. - Release the throttle immediately if value is exceeded. - Block the drive wheels. - Set the parking brake. - DO NOT apply the brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn the A/C OFF. - The vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. With the scan tool, enable the crankshaft position system variation learn procedure. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release the throttle when the fuel cut-off occurs. 8. The scan tool displays Learn Status-Learned this ignition: - If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. - If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. - If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The crankshaft position system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P1336 sets: Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - Crankshaft position sensor replacement - Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Page 12183 Registered And Non-Registered Trademarks Part 2 Molding Replacement - Rear Door Body Side (Chevrolet, GMC) Lower Side Moulding / Trim: Service and Repair Molding Replacement - Rear Door Body Side (Chevrolet, GMC) Molding Replacement - Rear Door Body Side (Chevrolet, GMC) Tools Required J 25070Heat Gun Removal Procedure 1. Remove the molding from the vehicle using the following procedure: 1. Heat the door side molding using a J 25070. Hold the heat gun approximately 152 mm (6 in) from surface. Apply heat using a circular motion for about 30 seconds. Important: Be careful not to scratch or chip the paint. 2. Peel the door side molding from the panel surface using a flat-bladed tool. 2. Remove all adhesive from the body panel and the back of the door side molding using a 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 3. Clean the body panel using Varnish Makers and Painters (VMP) naphtha. Installation Procedure 1. Ensure the painted body surface in the tape contact area is clean and dry. 2. Warm body panel with a heat lamp or heat gun if necessary, to a temperature between 18.8-41.1°C (66-100°F). 3. Remove the tape liner from the adhesive tape. Important: Do not touch the adhesive surface. 4. Ensure that the molding is aligned with the body panel. Press the door side molding to the body panel. 5. Hand roll the door side molding to the body in order to ensure proper adhesion. Page 11795 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 12914 Abbreviations And Meanings Part 3 Page 8757 Low Pressure Sensor / Switch: Description and Operation HVAC System - Automatic HVAC SYSTEM - AUTOMATIC A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 12 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 124 kPa (18 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275 kPa (40 psi). This enables the A/C compressor to turn back ON. Page 6666 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 12129 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 8172 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 13681 Involved are certain 2004 Buick Rainier, 2003-2004 Chevrolet TrailBlazer, GMC Envoy, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts Pre-ship Information - For US Only Important: An initial supply of flashers required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of July 18, 2005, and will be approximately 10% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Page 615 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 9177 Abbreviations And Meanings Part 10 Page 6820 Abbreviations And Meanings Part 24 Page 325 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 13832 Turn Signal/Hazard Flasher Module Page 8311 47. Connect the electrical connector to the A/C low pressure switch. 48. Install the lower air cleaner housing/washer solvent tank assembly onto the mounting studs. 49. Install the two air cleaner housing/washer tank assembly retaining nuts to the mounting studs. 50. Connect the washer pump hoses. 51. Connect the washer solvent tank electrical and install wiring harness to the retaining clips. 52. Install the air inlet duct to the lower air cleaner housing/washer solvent tank assembly. 53. Install the air cleaner filter element and air outlet duct. 54. Install the air cleaner cover. 55. Install the tender rear upper brace. 56. Connect the negative battery cable. 57. Recharge the refrigerant system. 58. Fill the cooling system. 59. Inspect the cooling system for leaks. 60. Leak test the refrigerant fittings using J 39400-A. Parts Information Warranty Information Page 9104 9. Position the headlamp wire harness (1) to the retaining clip. 10. Install and secure the headlamp wire harness in the retaining clip (1). 11. Install the grille. 12. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Page 13234 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 4530 Steps 20-22 Page 12970 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Specifications Page 4318 3. Connect the 24-way gray electrical connector (1) to the BCM. 4. Connect the 32-way tan electrical connector (2) to the BCM. 5. Connect the 40-way body wiring extension (1) to the BCM. 6. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. Page 12777 Specifications Water Pump: Specifications Water Pump Bolts ................................................................................................................................ ................................................. 10 Nm (89 inch lbs.) Page 10007 Diagnostic Tips Review # 3 - Denso Navigation Radios A/C - Intermittently Inoperative/Poor Performance Control Module HVAC: Customer Interest A/C - Intermittently Inoperative/Poor Performance Bulletin No.: 02-01-39-005A Date: August 17, 2005 TECHNICAL Subject: HVAC System Inoperative For A Drive Cycle, Poor HVAC System Performance In High Ambient Temperatures (Update HVAC Control Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to correct the RPO usage information below: RPO CJ2 = HVAC System Air Conditioner Front, Automatic Temperature Control, Auxiliary Temperature Control RPO CJ3 = HVAC System Air Conditioner Front, Manual Temperature Control, Auxiliary Temperature Control Please discard Corporate Bulletin Number 02-01-39-005 (Section 01 - HVAC). Condition Some customers may comment about no cold air from the heating, ventilation and air conditioning (HVAC) system during a drive cycle. This concern may occur at any time during the drive cycle and at any temperature setting. The HVAC system operation returns to normal after the vehicle has been keyed to off and restarted. This concern is intermittent and most likely to occur on hot days. This concern may be found on vehicles equipped with manual (CJ3) and automatic (CJ2) HVAC systems. Other customers may comment about poor HVAC system performance in high ambient temperature conditions. This concern may be present in automatic (CJ2) HVAC systems only. An HVAC control module software update was put into all production vehicles beginning in September 2002. Vehicles built in September 2002 and earlier may need this software update. Correction Update the HVAC control module using software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. This software update addresses both the intermittent no cooling and the poor performance concerns. If the software update does not correct the concerns, perform the HVAC Diagnostic System Check and repair as necessary. If the HVAC control module is replaced with a part from GMSPO, make sure the module has the latest software update. The module may need to be updated even though it is a new part. Warranty Information Disclaimer Page 8387 Abbreviations And Meanings Part 7 A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Page 1882 1. Install the air cleaner element (1) onto the air outlet duct (2) with a twisting and pushing motion. 2. Snap the air cleaner element (1) and air outlet duct (3) into the lower air cleaner housing/washer solvent tank assembly (2). 3. Install the air cleaner cover/resonator assembly (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the three air cleaner cover/resonator retaining screws (2) one shown, to 4 N.m (35 lb in). 4. Install the radiator air intake baffle if applicable. 5. Install the radiator support diagonal brace if applicable. A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 10173 Description and Operation Knee Diverter: Description and Operation KNEE BOLSTER The Knee Bolsters are designed to help restrain the lower torso of front seat occupants by absorbing the energy through the front seat occupant's upper legs. In a frontal collision the front seat occupant legs may come in contact with the knee bolsters. The knee bolsters are designed to crush or deform, absorbing some of the impact, which helps to reduce bodily injuries. The driver and passenger knee bolsters are located in the lower part of the instrument panel and must be inspected for damages after a collision. Page 3356 1. Install the inlet radiator hose clamps to the radiator hose (1). 2. Install the inlet radiator hose (1) to the radiator. 3. Reposition the inlet radiator hose clamp using J 38185. 4. Install the lower radiator support shield, if equipped. 5. Lower the vehicle. 6. Install the inlet radiator hose to the thermostat (1). 7. Reposition the inlet radiator hose using J 38185. 8. Fill the cooling system. Body VIN Code 6 Radiator Hose Replacement - Inlet (Body Vin Code 6 LL8 / GMT 370) Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the coolant. Page 3579 Powertrain Control Module (PCM) C1 Part 5 Page 4573 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Page 8531 For vehicles repaired under warranty, use the table. Disclaimer Page 13291 Registered And Non-Registered Trademarks Part 3 Page 13537 Door Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the rear door ajar switches in the door lock assemblies as one method to activate the alarm. The body control module (BCM) monitors rear door ajar switches via a discrete input from each rear passenger door ajar switch, if the BCM receives a ground signal from a rear passenger door ajar switch when the CTD system is armed, the BCM activates the alarm. The CTD system uses the LH front door ajar switch as one method to activate the alarm. The driver door module (DDM) monitors the LH door ajar switch via a discreet input from the door ajar switch, if the DDM receives a ground signal from the LH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the RH front door ajar switch as one method to activate the alarm. The passenger door module (PDM) monitors the RH door ajar switch via a discreet input from the door ajar switch, if the PDM receives a ground signal from the RH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the rear compartment liftgate/liftglass ajar switchs as one method to activate the alarm. The liftgate module (LGM) monitors the liftgate and liftglass ajar switch via a discreet input from the ajar switch, if the LGM receives a ground signal from the liftgate or liftglass ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. Page 6699 Abbreviations And Meanings Part 21 Page 13331 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6856 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 2801 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Page 8942 Impact Sensor: Diagrams Inflatable Restraint Side Impact Sensor (SIS) Inflatable Restraint Side Impact Sensor (SIS) - Left Page 2245 Fuse Block - Underhood C4 Part 4 Fuse Block - Underhood C5 Page 2149 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. See: Specifications/Capacity Specifications Page 10538 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 7369 Location View Page 1000 16. Remove the nut and bolt securing the coolant recovery reservoir. 17. Remove the coolant recovery reservoir with the accumulator attached. 18. Remove the evaporator tube nut at the evaporator. 19. Remove the evaporator tube from the evaporator 20. Using the J 43181, disconnect the heater hoses from the core. 20.1. Install the J 43181 to the heater core hose. 20.2. Close the tool around the heater core hose. 20.3. Firmly pull the tool into the quick connect end of the heater hose. 20.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 21. Disconnect the coolant bypass valve hose from the auxiliary rear heater line. 22. Disconnect the coolant bypass valve hose from the engine. 23. Disconnect the electrical connector from the coolant bypass valve. This connector will no longer be used. Tape off with electrical tape. 24. Disconnect the vacuum hose from the coolant bypass valve. 25. Remove the nut retaining the coolant bypass valve to the cowl and remove the coolant bypass valve with hoses attached. 26. Remove the heater hose quick connect retainers from the heater core pipes. 27. Remove the four nuts and the HVAC plate from the dash panel. 28. Attach the new auxiliary heater pump to the new bracket using the supplied retainers as shown. Note the position of the pump on the bracket. Page 12899 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 6058 Park/Neutral Position Switch (C2) Service and Repair Hood Latch Release Cable: Service and Repair Hood Latch Release Cable Replacement Removal Procedure 1. Remove the left front door sill panel. 2. Remove the left closeout/insulator panel. 3. Remove the grille. 4. Remove the hood latch. 5. Release the hood latch release cable from the hood latch assembly. 6. Attach a length of mechanic's wire to the exterior end of the cable, and note the routing of the cable for later installation. 7. Release the retainer that attaches the cable to the hood hold open rod bracket. 8. Feed the cable out from between the headlamp panel and the radiator, then over the top of the battery tray. 9. Push the cable grommet (1) through the bulkhead and into the interior of the vehicle. 10. Remove the nut (2) attaching the hood release handle (3) to the cowl trim panel on the left side. 11. Remove the cable from the release handle (3). 12. Pull the cable the rest of the way through the bulkhead and out from behind the sound insulation. 13. Detach the mechanics wire from the cable, leaving the wire in position for aid in installation of the cable. 14. Remove the cable from the vehicle. Installation Procedure 1. Attach the mechanics wire to the exterior end of the cable. 2. Using the mechanic's wire as an aid, guide the cable underneath the sound insulation and pass the exterior portion of the cable through the Page 2220 Fuse Block - Rear C2 Part 5 Page 550 Page 9388 Abbreviations And Meanings Part 22 Page 6982 Fuse Block - Underhood C4 Part 4 Fuse Block - Underhood C5 Instruments - Erratic Speedometer Operation Ground Strap: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 7118 Multiple Junction Connector: Diagrams C401 - C901 C401 (Body Type VIN 6) Part 1 Page 7291 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 7348 Fuse Block - Underhood C1 Part 5 Page 12994 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 2491 Compression Check: Testing and Inspection Engine Compression Test Tools Required J 38722 Compression Tester A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. Important: The battery must be at or near full charge. 1. Remove the air duct from the throttle control module. 2. Remove the ignition control modules. 3. Disable the fuel system. 4. Remove the spark clues. 5. Measure the engine compression, using the following procedure: 5.1. Firmly install J 38722 to the spark plug hole. 5.2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 5.3. Check and record the readings on J 38722 at each stroke. 5.4. Disconnect J 38722. 5.5. Repeat the compression test for each cylinder. 6. Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. 7. The following are examples of the possible measurements: - When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. - When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. - When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. - When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 8. Install the air duct to the throttle body. 9. Install the spark plugs. 10. Enable the fuel system. 11. Install the ignition control modules. Page 11998 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Page 6380 Page 10022 Compressor Hose Assembly Hose/Line HVAC: Service and Repair Compressor Hose Assembly COMPRESSOR HOSE ASSEMBLY REPLACEMENT (BODY VIN TYPE 3) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Remove the compressor hose assembly nut (3). 3. Remove the compressor hose assembly from the compressor (4). 4. Remove the sealing washers. 5. Remove the compressor suction hose nut from the accumulator. 6. Remove the compressor suction hose from the accumulator. 7. Remove the O-ring seal. 8. Remove the bolt from the lift bracket. 9. Remove the nut from the engine stud. 10. Remove the compressor discharge hose (2) from the condenser (4). 11. Remove the nut from compressor hose connection in driver wheel opening. 12. Remove the O-ring seals. 13. Cap or plug all of the open connections. INSTALLATION PROCEDURE Page 9558 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 8944 Impact Sensor: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. - Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. Page 11735 Door Lock Cylinder: Removal and Replacement Lock Cylinder Replacement - Door Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector from the door. 3. Remove the outside handle from the door. 4. Remove the lock cylinder from the door handle. Installation Procedure 1. Install the lock cylinder to the door handle. 2. Install the outside handle to the door. 3. Install the water deflector to the door. 4. Install the door trim panel to the door. Page 10313 Page 8198 Instrument Panel Carrier, Left And Right Page 13845 Turn Signal Switch: Service and Repair Multifunction Turn Signal Switch Housing Replacement Multifunction Turn Signal Switch Housing Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the steering wheel from the column. 3. Remove the ignition lock cylinder case assembly. 4. Remove the turn signal and multifunction switch assembly. 5. Slide the turn signal switch housing off of the steering column shaft assembly. Installation Procedure Important: The turn signal switch housing must be pressed firmly against the steering column tilt head in order for the screws from the turn signal and multifunction switch assembly screws to line up. 1. Slide the turn signal switch housing onto the steering column shah assembly. 2. Install the turn signal and multifunction switch assembly. 3. Install the ignition lock cylinder case. 4. Install the steering wheel onto the column. 5. Enable the SIR system. Page 2333 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Page 13155 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 9735 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Locations Engine Page 1120 Power Seat Switch: Diagrams Lumbar Adjuster Switch - Driver (w/o Memory) Page 10894 Registered And Non-Registered Trademarks Part 4 Page 3776 1. Install the air cleaner element (1) onto the air outlet duct (2) with a twisting and pushing motion. 2. Snap the air cleaner element (1) and air outlet duct (3) into the lower air cleaner housing/washer solvent tank assembly (2). 3. Install the air cleaner cover/resonator assembly (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the three air cleaner cover/resonator retaining screws (2) one shown, to 4 N.m (35 lb in). 4. Install the radiator air intake baffle if applicable. 5. Install the radiator support diagonal brace if applicable. Page 3480 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 12385 Power Seat Motor Position Sensor: Diagrams Position Sensor - Front Motor (w/Memory) Page 9332 Page 855 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 10357 Abbreviations And Meanings Part 10 Page 12912 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 61 Abbreviations And Meanings Part 6 Page 2790 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 10955 9. Install the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 02-08-62-004B Date: 060602 Body - Front Bumper Fascia Panel Wavy Bulletin No.: 02-08-62-004B Date: June 02, 2006 TECHNICAL Subject: Front Fascia Wavy (Install Dual Lock) Models: 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer EXT LS Model 2006-2007 Chevrolet TrailBlazer LS, TrailBlazer SS Supercede: This bulletin is being revised to add model years and material allowance. Please discard Corporate Bulletin Number 02-08-62-004A (Section 08 - Body Page 8541 For vehicles repaired under warranty, use the table. Disclaimer Page 12396 Power Seat Switch: Diagrams Lumbar Adjuster Switch - Driver (w/o Memory) Page 4244 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 4102 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 12063 WA800J/98 - WA805K/62 Page 595 Abbreviations And Meanings Part 7 Page 7484 C307 Part 2 Page 13053 5. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 6. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Service and Repair Steering Mounted Controls Transmitter: Service and Repair Steering Wheel Control Switch Assembly Replacement Removal Procedure 1. Remove the steering wheel. 2. Remove the shroud retaining screws from the back of the steering wheel. 3. Remove the shroud from the steering wheel. 4. Position a blunt ended tool into the wire harness cavity (1) and apply moderate pressure in order to partially remove the steering wheel control switch from the steering wheel. 5. Disconnect the steering wheel control switch electrical connector. Important: The bulbs in the steering wheel control switches are not serviceable. The switches should be replaced only as an assembly. Page 4080 Exhaust Manifold Heat Shield Heat Shield: Service and Repair Exhaust Manifold Heat Shield Exhaust Manifold Heat Shield Replacement Removal Procedure 1. Remove the air cleaner resonator outlet duct. 2. Remove the transmission filler tube stud nut from the A.I.R. adapter and move the filler out of the way. 3. Remove the oil level indicator tube. 4. Remove the oxygen sensor from the exhaust manifold. 5. Remove the 4 manifold heat shield nuts and remove the heat shield. Installation Procedure Page 11597 Disclaimer Page 13923 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 6871 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Testing and Inspection Oil Level Warning Indicator: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 7071 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 9390 Abbreviations And Meanings Part 24 A/T - Key Will Not Release From Ignition Lock Cylinder Automatic Transmission Shift Boot: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 12058 WA534F/54 - WA5456/43 Page 6686 Abbreviations And Meanings Part 8 Page 132 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Diagrams Transmission Range Switch Connector, Wiring Harness Side Page 12068 WA820K/94 - WA8554/40 Page 9086 Tighten Tighten the rear seat back cushion hinge cover screws to 2 N.m (18 lb in). Connector Views Fuse Block: Connector Views Fuse Block - Rear C1 Fuse Block - Rear C1 Part 1 Page 12872 Page 2778 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 3887 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Steering - Steering Column Squeaking/Rubbing Noise Steering Shaft Coupler: All Technical Service Bulletins Steering - Steering Column Squeaking/Rubbing Noise Bulletin No.: 02-02-35-006B Date: March 17, 2006 TECHNICAL Subject: Squeak, Rub/Scrub Type Noise in Steering Column (Lubricate Upper Intermediate Shaft Serration (Slip) Joint and Remove Material from Upper Intermediate Shaft Bushing) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to change the lubricant part number. Please discard Corporate Bulletin Number 02-02-35-006A (Section 02 - Steering). Condition Some customers may comment on a squeak noise coming from the steering column while turning the steering wheel. Some customers may also comment on a rubbing/scrubbing type noise/feel in the steering wheel during low speed turns/parking maneuvers. This condition may be more pronounced in cold temperatures. The rubbing/scrubbing noise condition affects vehicles built prior to VIN breakpoint 32214010 (Moraine, OH) and 36170447 (Oklahoma City, OK). Cause Inadequate distribution and amount of grease in the serration (slip) joint of the upper intermediate shaft may cause the squeak noise. The rubbing/scrubbing type noise may be due to an interference fit between the upper intermediate shaft boot seal and the intermediate shaft bushing. Correction Lubricate the upper intermediate shaft serration (slip) joint. After lubrication, remove material from the upper intermediate shaft bushing. Use the following procedure. 1. Remove the two screws that retain the left closeout/insulator panel to the instrument panel (IP). 2. Release the insulator panel retaining clip from the IP substrate and lower the panel. 3. Remove the push pin retainer and the LH floor air outlet duct from the heater module. 4. Insert the flexible applicator hose of the spray lubricant, P/N 89021668 (Canadian P/N 89021674), through the top, hollow end (1) of the intermediate shaft. Page 5379 15. Disconnect the rear oil cooler lines (2) from the front oil cooler lines (1). 16. Remove the oil cooler lines from the vehicle. Installation Procedure 1. Install the transmission oil cooler lines to the vehicle. 2. Install the transmission cooler lines to the transmission. Notice: Ensure that the cooler line being installed has a plastic cap on each end that connects to a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new plastic cap and position on to the cooler line prior to the cooler line installation. 3. Connect the rear cooler lines (2) to the front cooler lines (1). 4. Raise the transmission into position. 5. Install the front exhaust pipe assembly. 6. Install the transmission support. Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 8410 Registered And Non-Registered Trademarks Part 4 Page 2509 7. Remove the camshafts. Installation Procedure 1. Coat the camshaft journals, camshaft journal thrust face, and camshaft lobes with clean engine oil. 2. Install the intake and exhaust camshafts to their original positions. 3. Install the J 44221 with the camshaft flats up and the number 1 cylinder at top dead center. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Important: Install the camshaft caps onto their original locations. The camshaft caps are pin stamped for direction and numerical order. Page 8839 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Application and ID Relay Box: Application and ID Location View Application Table Part 1 Page 9926 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 3874 Page 1203 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine oil pan drain plug and drain the engine oil. 3. Remove the engine protection shield mounting bolts. 4. Remove the engine protection shield. 5. Disconnect the electrical connector from the engine oil level sensor. 6. Remove the engine oil level sensor mounting bolt. 7. Remove the engine oil level sensor. Page 14025 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 4412 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the fuel tank pressure harness connector. 3. Remove the fuel tank pressure sensor. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor seal. 2. Install the fuel tank pressure sensor. 3. Connect the fuel tank sensor harness connector. 4. Lower the vehicle. Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 13301 Page 2802 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 13225 Diagrams Mirror Switch, Driver Door Module (DDM) - C5 Page 1524 40.5. Route the other end of the harness along the rear of the engine compartment to the left side and secure to the cross bar and dash panel with tie straps. Page 1049 Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for inspecting the windshield wiper module, installing a breathable seal to the vent on the wiper motor cover if applicable, or if necessary, installing a new windshield wiper module. INSPECTION PROCEDURE 1. Using a flashlight, look down through the air inlet screen (1) at the location shown. ^ If the color of the can (2) on the wiper motor is SILVER, no repairs are required on the vehicle. ^ If the color of the can (2) on the wiper motor is BLACK, proceed to the section below titled, REPAIR PROCEDURE. REPAIR PROCEDURE 1. Verify that all of the functions of the wiper system (low, high, delay, etc.) operate properly. 2. Turn the key to the OFF position. 3. Open the hood. Page 8989 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at strategic locations on the vehicle. In the event of a collision, the SDM compares the signals from the internal and external sensors to a value stored in memory. When the generated signals exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator located in the IPC ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON, notifying the driver that a malfunction exist. In the event that ignition positive voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 3163 40.1. Install the ring terminal (black wire) to ground G103 (1), located on the right side inner tender. 40.2. Route the pump wiring harness along the existing right side forward lamp harness. 40.3. Connect the electrical connectors to the coolant bypass valve (1) and auxiliary heater pump (2). 40.4. Position the relays onto the inner wheelhouse panel near the rear of the engine compartment. Page 4663 Fuel Rail: Service and Repair FUEL RAIL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the intake manifold. 3. Before removal, clean the fuel rail assembly and the cylinder head with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent. 4. Disconnect the fuel pressure regulator vacuum line. 5. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. 6. Disconnect the fuel injector harness in-line connector. Page 581 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 5875 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Step 1 - 4 Wheel Bearings Diagnosis Step 5 - 7 Page 6405 Page 13701 Stop Lamp Switch Page 3904 Conversion - English/Metric Part 1 Interior - Cargo Cover Handle is Broken Cargo Cover: All Technical Service Bulletins Interior - Cargo Cover Handle is Broken Bulletin No.: 05-08-110-004A Date: May 02, 2006 TECHNICAL Subject: Cargo Cover Handle Broken (Replace Cargo Cover Handle - Service Part Available) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add the 2006 model year and the Saab 9-7X model information. Please discard Corporate Bulletin Number 05-08-110-004 (Section 08 - Body & Accessories). Condition Some customers may comment that the cargo cover handle is broken. Part returns have shown that the handle may be fractured at the locating pins. Correction DO NOT REPLACE THE CARGO COVER. Use the following steps the replace the cargo cover handle: 1. Using a flat-bladed tool, depress the two tabs that retain the handle to the cargo cover. 2. Remove the handle from the cargo cover. 3. Install the new handle to the cargo cover. Be sure that the two retaining tabs are released to secure the handle in position. Parts Information Page 8960 Page 9564 Parts Information Page 6663 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 9127 Page 10542 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 8275 Air Register: Service and Repair Rear Floor AIR OUTLET REPLACEMENT - REAR FLOOR REMOVAL PROCEDURE 1. Remove the console support bracket. 2. Remove the push pin (1). 3. Rotate the air outlet duct-rear (3) to remove from the console support bracket (1). 4. Remove the air outlet duct-rear from the vehicle. INSTALLATION PROCEDURE Page 6158 Page 12875 Page 9386 Abbreviations And Meanings Part 20 Page 12670 Air Dam: Service and Repair Air Intake Baffle Replacement - Radiator Air Intake Baffle Replacement - Radiator Removal Procedure 1. Open the hood. 2. Remove the push-pins that retain the baffle. 3. Remove the bolts that retain the baffle to the radiator support. 4. Remove the radiator baffle from the vehicle. Installation Procedure 1. Position the baffle to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the baffle to the body. Tighten the air intake baffle bolts to 2 N.m (18 lb in). 3. Install the push-pin retainers. Page 13991 Bus Bar Lead Terminal Repair BUS BAR LEAD TERMINAL REPAIR 1. Clean the repair area by buffing with fine steel wool. This removes the oxide coating formed during the window manufacture. IMPORTANT: The rear defogger bus bar lead wire, the antenna, or the defogger terminal may be reattached by resoldering using a solder containing 3 percent silver and a rosin flux paste. 2. Install the paste-type rosin flux in small quantities to the rear defogger bus bar lead wire antenna or the defogger terminal repair area using a brush. 3. Coat the solder iron tip with the solder. - Use only enough heat in order to melt the solder. - Use only enough solder in order to ensure a complete repair. 4. Install the solder to the feed bus bar or the ground bus bar. 5. Draw the soldering iron tip across the fluxed area, thinly coating the bus bar with solder. 6. Install a small amount of flux to the underside of the rear defogger bus bar lead wire antenna or the defogger terminal. 7. Align the spots with flux to the underside of the rear defogger bus bar lead wire, antenna, or defogger terminal. 8. Coat the tip of the soldering iron with solder. 9. Install the solder to the underside of the rear defogger bus bar lead wire antenna to the defogger terminal. 10. Draw the iron across the fluxed spot, thinly coating the spot of solder. 11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar. - Use pliers in order to hold the rear defogger bus bar lead wire antenna or the defogger terminal. - Apply the heat to the top of the rear defogger bus bar lead wire antenna or the defogger terminal. This causes the solder spot to melt and fuse together. - Do not remove the holding force until the solder has solidified. - Wipe off the excess flux with solvent. 12. Connect the electrical connector. Page 1643 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7535 4. Install the harness end bolts (2). 5. Install the fuse relay center cover (1) over the relay center bolts. Press downward to engage the tabs. 6. Install the junction block cover. Press downward to engage the tabs. A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Page 8349 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Suspension - Front/Rear Suspension Pop/Clunk/Snap Noises Stabilizer Link: All Technical Service Bulletins Suspension - Front/Rear Suspension Pop/Clunk/Snap Noises TECHNICAL Bulletin No.: 05-03-08-007A Date: March 31, 2008 Subject: Rattle, Clunk, Pop, Snap Noise from Front and/or Rear Suspension While Driving Over Rough, Uneven, Wash Board Road Surfaces (Replace Appropriate Stabilizer Link(s)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to update the Warranty information. Please discard Corporate Bulletin Number 05-03-08-007 (Section 03 - Suspension). Condition Some customers may comment on a rattle, clunk, pop, loose lumber-type noise coming from the front and/or rear suspension while driving over rough uneven roads. Cause The front and/or rear stabilizer links, may develop additional clearance in the ball joint links leading to a noise concern. Correction 1. Road test the vehicle and verify if the noise is coming from the front or rear, left or right of the vehicle. It is possible in some circumstances that the noise may be coming from the front and rear suspension. 2. Once it is determined that the noise is coming from the front or rear, left or right of the vehicle, raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information (SI Document ID # 1253321). Caution: DO NOT DRIVE the vehicle on highways or at a high rate of speed while the stabilizer link(s) are removed/disconnected from the vehicle. ONLY test drive the vehicle in a parking lot or on a side street. Driving the vehicle with the link(s) removed/disconnected may reduce vehicle stability. 3. Remove or disconnect the suspect stabilizer link(s) from the appropriate stabilizer shaft and re-road test the vehicle with the links disconnected to verify the source of the noise. ^ If the noise is still present with the suspect link(s) removed the source of the noise is NOT the stabilizer links. Refer to the information below for diagnostic assistance. ^ Service Bulletin - Rattle From Front of Vehicle (Adjust Hood Latch Following New Procedure) # 03-08-63-003 or newer (SI Document ID # 1410372) ^ Service Bulletin - Rattle Noise Under Hood (Reposition Hood Prop Rod) # 04-08-63-005 or newer (SI Document ID # 1527265) ^ Service Information - Suspension - Suspension General Diagnosis in the appropriate SI Document. ^ If the noise is no longer present with the suspect stabilizer link(s) removed continue with the next step. 4. Replace the suspect stabilizer link(s) (see parts information below). Refer to the appropriate Service Information for the replacement procedure. Page 6760 Page 4123 Abbreviations And Meanings Part 9 Page 10842 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 12972 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 1721 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 3222 approximately 25 mm (1 in) away from the connector so the wires can be fed into the slot. Feed the wires into the slot and install the harness to the plastic guide. Connect the harness electrical connector to the cooling fan clutch. Install the cooling fan. Refer to the Cooling Fan and Shroud Replacement procedure in the Engine Cooling sub-section of SI. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 81 Abbreviations And Meanings Part 26 Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement - Front (Chevrolet (X88) ONLY) Removal Procedure 1. Remove the grille 2. Remove the front fascia. 3. Remove the front impact bar. 4. Place the impact bar on a clean, prepared surface. 5. Remove the bolt that retains the tow hook to the impact bar. 6. Remove the tow hook from the impact bar. Installation Procedure 1. Install the tow hook to the impact bar, ensuring that the locating pin is properly indexed to the impact bar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt which retains the tow hook to the impact bar. Tighten the bolt to 50 N.m (37 lb ft). 3. Install the impact bar. 4. Install the fascia. 5. Install the grille. Page 2508 Camshaft: Service and Repair Camshaft Replacement Camshaft Replacement ^ Tools Required J 44221 Camshaft Holding Tool - J 44222 Camshaft Sprocket Holding Tool - J 36660-A Torque/Angle Meter Removal Procedure 1. Remove the camshaft cover. 2. Remove the intake and the exhaust camshaft sprocket bolts. 3. Install the J 44222 onto the cylinder head and adjust the horizontal bolts into the camshaft sprockets in order to maintain chain tension and keep from disturbing the timing chain components. 4. Carefully move the sprockets with the timing chain, off of the camshafts. 5. Remove the camshaft cap bolts. Important: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed. 6. Remove the camshaft caps and store. Service and Repair Passenger Assist Handle: Service and Repair Assist Handle Replacement Removal Procedure 1. Use a flat bladed tool in order to open the front and rear bezel covers. 2. Position the stem of a flat bladed tool at the rear bezel. 3. Push the rear bezel rearward 6 mm (1/4 in) and pull down on the handle in order to release the roof panel retaining tab. 4. Position the stem of a flat bladed tool at the inside edge of the front bezel assembly. 5. Push the front bezel assembly forward 6 mm (1/4 in) and pull down on the handle in order to release the roof panel retaining tab. 6. Partially lower the headliner in order to expose the rear handle retaining tab (1). 7. Insert the tip of a flat bladed tool into the rear retaining tab (1). 8. With the retaining tab (1) released, pull down on the handle in order to release the roof panel tab from the bezel. Locations Engine, Left Front Page 949 Powertrain Control Module (PCM) C2 Part 4 Multifunction, Turn Signal Switch Replacement Turn Signal Switch: Service and Repair Multifunction, Turn Signal Switch Replacement Multifunction, Turn Signal Switch Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the upper and lower trim covers. 3. Tilt the column to the CENTER position. 4. Disconnect the connectors from the turn signal and multifunction switch assembly. Remove 2 pan head tapping screws from the turn signal and multifunction switch assembly. 5. Remove the turn signal and multifunction switch assembly. Installation Procedure Important: The electrical contact on the turn signal and multifunction switch assembly must rest on the turn signal cancel cam assembly. 1. Install the turn signal and multifunction switch assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Secure by using 2 pan head tapping screws. - Tighten the screw on the top of the column to 3 Nm (27 inch lbs.). - Tighten the screw in the front to 7 Nm (62 inch lbs.). 3. Connect the connectors to the turn signal and multifunction switch assembly. 4. Install the upper and lower trim covers. 5. Enable the SIR system. Page 6952 Fuse Block - Rear C1 Part 5 Lighting - Tail Lamp(s) Inoperative Tail Lamp Socket: All Technical Service Bulletins Lighting - Tail Lamp(s) Inoperative Bulletin No.: 03-08-42-006B Date: May 26, 2004 INFORMATION Subject: Tail Lamp Circuit Board Now Available For Service Use Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add a part number. Please discard Corporate Bulletin Number 03-08-42-006A (Section 08 - Body and Accessories). A new tail lamp circuit board is now available for service use. If normal diagnosis of a vehicle leads to a failed tail lamp bulb, inspect the bulb socket to ensure proper fit of the bulb into the socket. If the bulb is found to be loose, or if the circuit board has failed, replace both tail lamp circuit boards with the new part number from GMSPO. Technicians are to replace the tail lamp circuit boards, on both sides of the vehicle, using the following procedure: 1. Remove the tail lamp assembly from the vehicle. 2. Remove the tail lamp circuit board from the tail lamp assembly. 3. Inspect for loose tail lamp bulbs in the tail lamp circuit board. Replace the tail lamp bulb and the tail lamp circuit board if necessary. 4. Install the tail lamp circuit board. 5. Install the tail lamp assembly. 6. Replace the tail lamp circuit board on the opposite side of the vehicle using the above procedure. 7. Verify the operation of the tail lamps. Parts Information Page 4279 Abbreviations And Meanings Part 13 Page 5162 Automatic Transmission Shift Lock Control Solenoid Page 13186 5. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 6. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Page 10497 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 8637 7. Remove the heater outlet hose (7) from the outlet hose fitting. 8. Remove the heater outlet hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185. 4. Install the heater outlet hose (3) to the heater core (1). 5. Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Install the transmission. 7. Install the generator. 8. Fill the cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. With RPO Code LM4 HEATER HOSE REPLACEMENT - OUTLET (WITH RPO CODE LM4) See: Application and ID/RPO Codes TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the coolant bypass valve. 2. Remove the transmission. Description and Operation Glove Compartment Lock Cylinder: Description and Operation KEY IDENTIFICATION AND USAGE The lock cylinder keyway is designed so that other model keys will not enter a current model lock cylinder. A single key is used for all locks on the vehicle. The key identification is obtained from the four-character key code stamped on the knockout portion of the key head. Knock the plugs out of the key head after code numbers have been recorded. The code list, available to owners of key cutting equipment from equipment suppliers, determines the lock combinations from the code numbers. CUTTING KEYS After the code has been determined from the code list or the key code diagram, perform the following steps: 1. Cut a blank key to the proper level of each of the tumbler positions. 2. Inspect the key operation in the lock cylinder. REPLACEMENT LOCK CYLINDERS New lock cylinders (except ignition lock cylinders) are available from the service parts warehouse with new lock cylinder locking bars. The tumblers are also available and must be assembled into the cylinder as recommended. LOCK CYLINDER TUMBLER OPERATION All lock tumblers are shaped alike with the exception of the notched position on one side. As the key is inserted into the lock cylinder, the tumblers are lowered to the correct height so that notches on each tumbler are at the same level. When the notches on all 6 tumblers line up, 2 small springs push the side bar into the notches, allowing the cylinder to turn in the cylinder bore. Five types of tumblers are used in making the lock combinations, and each is coded and stamped with a number between 1 and 5. Page 13508 Cornering Lamp - Right Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 10214 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 12783 Page 12121 Page 5130 Automatic Transmission Shift Lock Control Solenoid Page 6854 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Fuel Injector Coil Test Fuel Injector: Testing and Inspection Fuel Injector Coil Test CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. DIAGNOSTIC AIDS - Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that is causing the condition. - Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. - Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. TEST Page 1727 Conversion - English/Metric Part 1 Page 11895 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. Important: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 3. Install the actuator to the top of the latch. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 screws that retain the actuator (1) to the lock. Tighten the screws to 0.75 N.m (6 lb in). 5. Install the lock to the door. 6. Install the water deflector. 7. Install the door trim panel. Page 11929 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lift up on the front edge of the door lock and side window switch (1) in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. Remove the electrical connector (2) from the memory seat switch. 4. Remove the memory seat switch from the lock and door lock and side window switch (1). INSTALLATION PROCEDURE Page 9630 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 3187 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Service and Repair Radiator Cooling Fan Motor Relay: Service and Repair Cooling Fan Relay Replacement Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the underhood electrical center cover. 2. Using the J 43244, remove the cooling fan relay (3). Installation Procedure NOTICE: Installation of the proper relay is critical. If an enhanced relay equipped with a diode is installed into a position requiring a standard relay equipped without a diode; excessive current will damage any components associated with the relay or its associated circuits. 1. Install the cooling fan relay (3). 2. Install the underhood electrical center cover. Page 6506 Disclaimer Page 5733 Page 8497 HVAC Control Module C1 Part 2 Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 6.6L (7.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Page 1100 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle Installation Procedure 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. Important: When replacing the driver door module, the set up procedure must be performed. 4. If replacing the driver door module, program the driver door module. Refer to Service Programming System (SPS) (Remote Procedure) Service Programming System (SPS) (Pass-Thru Procedure) Service Programming System (SPS) (Off Board Remote Procedure) Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming and Personalization Description and Operation in Personalization. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Switch Replacement - Door Lock and Side Window - Passenger Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure Page 13287 Abbreviations And Meanings Part 25 Page 7266 Abbreviations And Meanings Part 2 Page 9888 1. Position the memory seat switch to the lock and door lock and side window switch (1). 2. Connect the electrical connector (2) to the memory seat switch. 3. Install the door lock and side window switch (1). Verify that the front retaining clips and the rear retaining clips are fully seated. Page 3692 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 9902 Page 1497 For vehicles repaired under warranty, use the table. Disclaimer Page 4558 Disclaimer Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 3205 Coolant Reservoir: Service and Repair Coolant Recovery Reservoir Replacement Removal Procedure 1. Remove the air cleaner assembly. 2. Remove the bracket bolt securing the accumulator to the coolant recovery reservoir (1). 3. Move the accumulator out of the way. 4. Remove the coolant hoses from the coolant recovery reservoir and plug the hoses and the coolant recovery reservoir outlets with suitable plugs (2). 5. Remove the nut and bolt securing the coolant recovery reservoir. 6. Remove the coolant recovery reservoir. Installation Procedure 1. Install the coolant recovery reservoir. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the retaining bolt to the front wheel house panel. Tighten the bolt to 12 Nm (106 inch lbs.). 3. Secure the coolant recovery reservoir to the wheel house panel with the nut. Tighten the nut to 10 Nm (88 inch lbs.). 4. Install the coolant hose to the coolant recovery reservoir (2). 5. Install the accumulator to the coolant recovery reservoir and secure the accumulator with the bracket and the bolt (1). 6. Install the air cleaner assembly. Page 2924 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 1294 Door Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the rear door ajar switches in the door lock assemblies as one method to activate the alarm. The body control module (BCM) monitors rear door ajar switches via a discrete input from each rear passenger door ajar switch, if the BCM receives a ground signal from a rear passenger door ajar switch when the CTD system is armed, the BCM activates the alarm. The CTD system uses the LH front door ajar switch as one method to activate the alarm. The driver door module (DDM) monitors the LH door ajar switch via a discreet input from the door ajar switch, if the DDM receives a ground signal from the LH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the RH front door ajar switch as one method to activate the alarm. The passenger door module (PDM) monitors the RH door ajar switch via a discreet input from the door ajar switch, if the PDM receives a ground signal from the RH door ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. The CTD system uses the rear compartment liftgate/liftglass ajar switchs as one method to activate the alarm. The liftgate module (LGM) monitors the liftgate and liftglass ajar switch via a discreet input from the ajar switch, if the LGM receives a ground signal from the liftgate or liftglass ajar switch when the CTD system is armed the message is communicated through the serial data circuit to the BCM and the alarm is activated. Page 7269 Abbreviations And Meanings Part 5 Page 8184 Wheel Nut Torque Sequence Page 2233 Fuse Block - Underhood C1 Part 6 Fuse Block - Underhood C2 Page 9496 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 778 service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers, possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in Page 9837 Registered And Non-Registered Trademarks Part 3 Page 953 Powertrain Control Module (PCM) C3 Part 2 Page 4194 Engine Oil Level And Temperature Sensor Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 542 Page 12946 Brake Warning Indicator: Description and Operation Brake Warning Indicator The Instrument Panel Cluster (IPC) illuminates the brake warning indicator when one or more of the following occurs: ^ The Body Control Module (BCM) detects that the park brake is engaged. The IPC receives a class 2 message from the BCM requesting illumination. ^ The Electronic Brake Control Module (EBCM) detects a low brake fluid condition. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The EBCM detects an ABS malfunction which disables Dynamic Rear Proportioning (DRP). The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check at the start of each ignition cycle. The brake warning indicator illuminates for approximately 3 seconds before turning OFF. ^ The IPC detects a loss of class 2 communications with the BCM or with the EBCM. Page 10918 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). 7. Disconnect the body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. Page 11340 Liftgate Module (LGM) C2 (Except XUV) Page 6583 1. Install sensor into the hub and bearing assembly (6). ^ Tighten the sensor mounting screw (5) to 18 Nm (13 ft. lbs.). Important: The new sensor has new mounting clips already installed on the wire. DO NOT reuse the old clips. 2. Connect the wheel speed sensor electrical connector (2). 3. Install wheel speed sensor mounting clip to the frame rail. 4. Install the wheel speed sensor mounting clip to the control arm. 5. Install the hub and rotor. 6. Install brake caliper. 7. Install tire and wheel. Page 8248 5. Remove the rear mode actuator retaining screws. 6. Disconnect the electrical connector. 7. Remove the rear mode actuator. INSTALLATION PROCEDURE 1. Install the mode actuator. 2. Connect the electrical connector. 3. Install the screws to the mode actuator. Locations Air Suspension Sensor - LR Page 11723 9. Release the five screws that retain the rear quarter trim panel to the body. 10. Remove the rear quarter trim panel from the vehicle. Installation Procedure 1. Install the auxiliary power outlet to the trim panel. 2. Position the trim panel to the vehicle. 3. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 4. Index the locating tabs on the trim panel to the holes in the body. 5. Connect the wiring harness connector to the auxiliary power outlet. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the five screws that the retain the rear quarter trim panel to the body. Tighten the rear quarter trim panel screws to 2.5 N.m (22 lb in). 7. Install the seat belt lower anchor. Tighten the seat belt anchor bolt to 70 N.m (52 lb ft). 8. Install the left rear door sill panel. 9. Install the liftgate sill plate. 10. Install the left body side window forward garnish molding. 11. Install the left body side window rear garnish molding. 12. Return the third row seats to the upright position. 13. Install the cargo shelf. Trim Panel Replacement - Rear Quarter - Left (TrailBlazer, Envoy, Bravada) Trim Panel Replacement - Rear Quarter - Left (Trailblazer, Envoy, Bravada) Removal Procedure Page 2465 Wheel Fastener: Specifications Wheel Nut 140 Nm 103 lb. ft. OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Locations Automatic Transmission Page 9024 5. Install the seat belt into the retractor bracket by guiding the seat belt through the slot in the bracket. 6. Install the seat back panel to the seat back frame. 7. Install the seat back pad and cover. 8. Slide the front seat back seat belt bezel onto the seat belt. 9. Install the seat belt bezel to the retractor bracket with the screw. Tighten Tighten the front seat back seat belt bezel screw to 6 N.m (53 lb in). 10. Install the seat belt anchor to the seat adjuster assembly with the nut. Ensure that the seat belt webbing is not twisted. Tighten Tighten the seat back anchor nut to 52 N.m (38 lb ft). 11. Install the seat trim panel. Page 12466 1. Install the trim panel to the power seat by performing the following steps: 1. Align the trim panel to the seat assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws retaining the trim panel to the seat assembly. Tighten the trim panel screws to 3 N.m (26 lb in). 3. Install the 3 seat switch bezel mounting screws. Tighten the seat switch bezel mounting screws to 3 N.m (26 lb ft). 2. Install the trim panel to the manual seat by performing the following steps: 1. Install the screws in the trim panel. 2. Install the lumbar support knob. 3. Install the seat back recliner handle. Seat Cushion Cover and Pad Replacement - Front Seat Cushion Cover and Pad Replacement - Front Removal Procedure 1. Remove the 3 seat switch bezel screws. 2. Remove the 4 nuts that retain the seat pan to the seat adjuster assembly. 3. Remove the clip from the front outboard seat pan stud, if equipped. Discard the clip. Page 13084 Page 6783 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 11007 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 12991 Conversion - English/Metric Part 2 Page 4163 Steps 19-21 Page 6180 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Page 11206 For 2007 vehicles repaired under warranty, use the table. Disclaimer Page 7520 Relay Box: Service and Repair Rear Electrical Center or Junction Block Replacement REAR ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a cargo position. 4. Remove the rear electrical center cover. 5. Remove the battery feed terminal nut (2) from the junction block. 6. Remove the body control module (BCM) from the rear electrical center. 7. Fully loosen the 3 bolts (1) that retain the junction block to the electrical connectors. Page 1655 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Diagrams Camshaft Actuator Solenoid Assembly Page 6143 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Locations Electronic Components Page 1018 33. Install the new hose, # 1003 (L6 engine) or # 1004 (V8 engine) onto the auxiliary heater pump inlet port. Connect the other quick connect end to the engine. Page 5989 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13708 Turn Signal/Multifunction Swtich C3 Page 13935 Abbreviations And Meanings Part 5 Page 7481 C305 Part 3 HVAC System - Manual Low Pressure Sensor / Switch: Description and Operation HVAC System - Manual HVAC SYSTEM - MANUAL A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 12 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 124 kPa (18 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275 kPa (40 psi). This enables the A/C compressor to turn back ON. Page 248 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 1758 Abbreviations And Meanings Part 22 A/T - Oil Cooler Flushing/Flow Check Procedures Transmission Cooler: All Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Page 12026 WA812K/88 - WA813K/89 Page 3592 1. Install the PCM mounting studs to the intake manifold, if removed. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the studs to 6 N.m (53 lb in). 2. Install the PCM (2) to the intake manifold. 3. Install the PCM mounting nuts and bolts (4). Tighten Tighten the nuts and bolts to 10 N.m (88 lb in). 4. Install the PCM harness connectors (3) to the PCM body. 5. Tighten the PCM harness connector retaining bolts (1). Tighten Tighten the bolts to 8 N.m (71 lb in). 6. If a new PCM is being installed, the PCM must be programmed. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. See: Testing and Inspection/Programming and Relearning Page 10763 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 11464 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 10442 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 4515 4. Tighten the throttle body clamps (2). Tighten the clamps to 4 Nm (35 lb in) 5. Connect the fuel pressure regulator vacuum supply hose to the air cleaner outlet resonator. 6. Lubricate the inner diameter of the crankcase ventilation hose. 7. Connect the crankcase dirty air hose to the intake manifold. 8. Connect the crankcase dirty air hose to the PCV orifice tube. Page 13246 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 8251 Air Door Actuator / Motor: Service and Repair Revised Mode Actuator This article has been updated with bulletin No. 03-01-39-013. REVISED MODE ACTUATOR REPLACEMENT PROCEDURE REMOVAL 1. Remove the left floor air outlet duct. 2. Disconnect the electrical connector from the mode actuator. 3. Remove the screws from the mode actuator (3). 4. Remove the mode actuator. INSTALLATION 1. Install the mode actuator (3). NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws to the mode actuator (3). TIGHTEN Screws to 1.9 Nm (18 lb in). 3. Install the air outlet duct. Engine Controls - A/T Slipping/No SES Lamp/No DTC Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - A/T Slipping/No SES Lamp/No DTC Set Transmission Slipping or Torque Converter Clutch (TCC) Inoperative with No SES Light Displayed and No DTC P1870 (Reprogram PCM and Diagnose Vehicle Using P1870 Diagnostic Table) # 03-07-30-001A - (Mar 14, 2005) Models: 2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 GMC Envoy, Envoy XL 2003 Oldsmobile Bravada Built Within the Build Dates shown. This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 03-07-30-001 (Section 07 - Transmission/Transaxle) Condition Some customers may comment that the transmission appears to be slipping or that the vehicle has no TCC apply. This condition should not be confused with a noisy cooling fan. Refer to Corporate Bulletin Number 99-07-30-016B for additional information on fan noise. Investigation of the condition may show no fail records, freeze frame or DTC associated with the condition. This condition might normally have set diagnostic trouble code (DTC) P1870. Important: Please note that this is a MISSING DTC P1870. This condition will NOT cause a DTC P1870 to be set. Cause The operating software may not allow DTC P1870 (Transmission Component Slipping) diagnostic test to run. This condition is not an impairment to the operation of the vehicle or the transmission. Correction The vehicle should be checked to verify DTC P1870 is supported in the operating software. 1. Install the scan tool. 2. Navigate to "Specific DTC." 3. Enter P1870. 4. If the DTC is supported, the scan tool will report the status of DTC P1870. Continue with normal service diagnostics. 5. If the DTC is not supported, the scan tool will report "Invalid DTC." The vehicle PCM must be reprogrammed using TIS version 9, broadcast in August 2002, or newer, and then diagnosed for no TCC operation using the SI information for P1870. Warranty Information Page 7103 C306 Page 39 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 11137 Disclaimer Service Procedure 1. Ensure that the rear rocker panel in the tape contact area (1) is clean and dry. Use a non oil based cleaner, preferably isopropyl alcohol. For Chevrolet TrailBlazer EXT with molded-in-color rear rocker, coat the top of the rocker with adhesion promoter, P/N 12378462 (U.S.), 10953554 (Canada), or equivalent and then allow it to dry. 2. With the door closed, trace the contour of the door using a china marker or grease pencil. Hold the taper of the marker to the door as shown. Page 13250 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Locations Engine, Left Side Page 3458 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 2024 7. Remove the heater outlet hose (7) from the outlet hose fitting. 8. Remove the heater outlet hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. 2. Install the heater outlet hose (7) to the outlet hose fitting. 3. Position the outlet heater hose clamp (6) at the outlet hose fitting using J 38185. 4. Install the heater outlet hose (3) to the heater core (1). 5. Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Install the transmission. 7. Install the generator. 8. Fill the cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. With RPO Code LM4 HEATER HOSE REPLACEMENT - OUTLET (WITH RPO CODE LM4) See: Application and ID/RPO Codes TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the coolant bypass valve. 2. Remove the transmission. Page 11703 2. Release the clips that retain the garnish molding to the liftgate. 3. Remove the wire harness (1) from the slot located on the garnish molding. 4. Remove the garnish molding from the liftgate. INSTALLATION PROCEDURE 1. Position the garnish molding to the liftgate. 2. Install wire harness (1) into the slot located on the garnish molding. 3. Index the locating tabs to the corresponding holes in the liftgate. 4. Index the retaining clips to the liftgate. 5. Push the garnish molding into the liftgate in order to fully seat the retaining clips. 6. Close the liftgate. Garnish Molding Replacement - Windshield Pillar GARNISH MOLDING REPLACEMENT - WINDSHIELD PILLAR REMOVAL PROCEDURE Page 9692 Parts Information Page 6874 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Camshaft Actuator System Camshaft Position Sensor: Description and Operation Camshaft Actuator System CAMSHAFT POSITION (CMP) ACTUATOR SYSTEM The Camshaft Position Actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation control, a wider engine torque range, improved gas millage, and improved engine idle stability. The CMP Actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. CMP ACTUATOR SYSTEM OPERATION The CMP Actuator system is controlled by the Powertrain Control Module (PCM). The PCM sends a pulse width modulated 12 volt signal to a Camshaft Position (CMP) Actuator Solenoid in order to control the amount of engine oil flow to a cam Phaser passage. There are two different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The Cam Phaser is attached to a camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position. Engine oil pressure, viscosity, temperature and engine oil level can have an adverse affect on cam phaser performance. The PCM calculates the optimum cam position through the following inputs: Engine Speed - Manifold Absolute Pressure (MAP) - Throttle Position (TP) Indicated Angle - Crankshaft Position (CKP) - Camshaft Position (CMP) - Engine Load. - Barometric (BARO) Pressure The Cam Phaser default position is 0 degrees. The PCM uses the following inputs before assuming control of the cam phaser: Engine Coolant Temperature (ECT) - Closed Loop Fuel Control - Engine Oil Temperature - Engine Oil Pressure - Engine Oil Level - CMP Actuator Solenoid circuit state - Ignition 1 signal voltage - Barometric (BARO) Pressure CMP ACTUATOR SOLENOID CIRCUIT DIAGNOSTICS The PCM monitors the control circuits of the CMP Actuator Solenoid for electrical faults. The PCM has the ability to determine if a control circuit is open, shorted high, and shorted low. If the PCM detects a fault with a CMP Actuator Solenoid circuit a Diagnostic Trouble Code (DTC) will set. CMP ACTUATOR SYSTEM PERFORMANCE DIAGNOSTICS The PCM monitors the performance of the CMP Actuator system by monitoring the actual and desired positions of a cam phaser. If the difference between the actual and desired position is more than a calibrated angle for more than a calibrated amount of time, a DTC will set. Page 4256 Various symbols in order to describe different service operations. Page 6236 Brake Warning Indicator: Description and Operation Brake Warning Indicator The Instrument Panel Cluster (IPC) illuminates the brake warning indicator when one or more of the following occurs: ^ The Body Control Module (BCM) detects that the park brake is engaged. The IPC receives a class 2 message from the BCM requesting illumination. ^ The Electronic Brake Control Module (EBCM) detects a low brake fluid condition. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The EBCM detects an ABS malfunction which disables Dynamic Rear Proportioning (DRP). The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check at the start of each ignition cycle. The brake warning indicator illuminates for approximately 3 seconds before turning OFF. ^ The IPC detects a loss of class 2 communications with the BCM or with the EBCM. HVAC System - Manual Control Assembly: Diagrams HVAC System - Manual HVAC Control Module C1 Part 1 Page 8455 Installation Procedure Important: If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant System Capacities for the capacity information. 1. Install the condenser to the radiator. Notice: Refer to Fastener Notice in the Preface section. 2. Install the condenser to the radiator bolts. Tighten Tighten the bolts to 9 Nm (80 lb in). 3. Install the condenser LH upper bracket bolt and bracket. Tighten Tighten the bolt to 9 Nm (80 lb in). 4. Install the studs to the condenser inlet and outlets. Tighten Tighten the studs to 4.5 Nm (40 lb in). 5. Install the evaporator tube (4) to the condenser. 6. Install the evaporator tube nut (5) to the condenser. Tighten Tighten the nut to 28 Nm (21 lb ft). 7. Install the upper radiator support bar. 8. Install the bolts to the upper radiator support bar. Tighten Tighten the bolts to 50 Nm (37 lb ft). 9. Install the radiator diagonal base. 10. Install the head lamp housing panel. 11. Install the hood latch. Page 7822 Ball Joint: Testing and Inspection Ball Joint Inspection Tools Required ^ J 8001 Dial Indicator or Suitable Dial Indicator Upper Ball Joint Inspection Important: ^ The vehicle must rest on a level surface. ^ The vehicle must be stable. Do not rock the vehicle on the floor stands. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Clean and inspect the ball joint seal for cuts or tears. If the ball joint seal is damaged, replace the ball joint. Refer to Upper Control Arm Ball Joint Replacement or Upper Control Arm Replacement. 3. Support the lower control arm with a floor stand as far outboard as possible and raise suspension to just below the ride height. 4. Install the J 8001 or a suitable dial indicator in a way to measure the vertical lash in ball joint. Notice: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). 5. Apply downward force to the upper control arm and zero the indicator. 6. Apply upward force to the upper control arm and check the dial indicator. 7. If the dial indicator reading is more than 1.524 mm (0.060 in), replace the upper ball joint. Refer to Upper Control Arm Ball Joint Replacement or Upper Control Arm Replacement. Lower Ball Joint Inspection Page 12225 Memory Seat Module - Driver C2 Part 1 Page 1154 Sunroof / Moonroof Switch: Service and Repair SUNROOF SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the overhead console in order to access the sunroof switch. 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat bladed tool carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. INSTALLATION PROCEDURE 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. Locations Instrument Harness, Instrument Panel Page 11769 Page 4199 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield. 3. Remove the electrical connector from the oil pressure switch. 4. Remove the oil pressure switch. Installation Procedure NOTICE: Refer to Fastener Notice in Service Precautions. See: Engine, Cooling and Exhaust/Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the oil pressure switch. Tighten the oil pressure switch to 20 Nm (15 ft. lbs.). 2. Install the electrical connector to the oil pressure switch. 3. Install the engine shield. 4. Lower the vehicle. Page 10337 Various symbols in order to describe different service operations. Page 2959 Registered And Non-Registered Trademarks Part 5 Page 12815 Conversion - English/Metric Part 2 Locations Engine, Left Side Page 11142 Page 11857 Front Passenger Door Module (FPDM) - C2 Part 1 Page 7471 C201 Part 4 Page 3497 Abbreviations And Meanings Part 14 Page 13103 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 10119 Page 3512 Registered And Non-Registered Trademarks Part 3 Page 9629 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 11006 Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Only if necessary remove the fuel tank shield. IMPORTANT: Due to an access hole in the fuel tank shield, removal of the shield should not be necessary to access the fuel pressure service connection. 3. Remove the fuel pressure service connection cap, located near the fuel filter. 4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Turn ON the ignition. 6. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 8. Command the fuel pump ON with a scan tool. 9. Close the bleed valve on the fuel pressure gage. 10. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. Page 13892 Locations Electronic Components Page 3906 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 4504 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Canister/Fuel Tank (Vent Pipe) REMOVAL PROCEDURE CAUTION: Refer to Fuel and EVAP Pipe Caution in Service Precautions. NOTE: Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Service Precautions. 1. Remove the fuel tank. EVAP Vent Valve 2. Disconnect the evaporative emission (EVAP) vent pipe (3) from the EVAP canister vent valve (1). 3. Remove the EVAP vent pipe from the fuel tank retainers. INSTALLATION PROCEDURE EVAP Vent Valve 1. Install the EVAP vent pipe to the fuel tank retainers. 2. Connect the EVAP vent pipe (3) to the EVAP canister vent valve (1). 3. Install the fuel tank. Page 6330 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II00, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 12880 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 4447 Heated Oxygen Sensor (HO2S) 1 Locations Body Control Module: Locations Body Wiring Harness Extension Harness Page 3915 Abbreviations And Meanings Part 2 Page 7872 10. Remove the air spring level sensor to the frame mounting bolts. 11. Remove the air spring level sensor. Installation Procedure 1. Install the air spring level sensor link to the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not remove the air spring level sensor locating pin until the air spring level sensor has been properly aligned and the proper D height has been measured and maintained. 2. Install the air spring level sensor to the frame mounting bolts. Tighten the air spring level sensor to the frame mounting bolts to 8 Nm (6 lb ft). Page 9781 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 12813 Various symbols in order to describe different service operations. Page 13337 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 1133 1. Remove the 3 screws that retain the switch bezel to the seat. 2. Partially remove the switch bezel from the seat. 3. Remove the seat switches from the switch bezel by releasing the retaining tabs. 4. Remove the lumbar switch from the switch bezel by releasing the retaining tabs. 5. Remove the switch bezel from the seat. INSTALLATION PROCEDURE 1. Install the lumbar switch to the switch bezel, verifying that the retaining tabs are fully seated. Page 7086 C108 Part 2 Page 7361 Fuse Block - Underhood C4 Part 4 Fuse Block - Underhood C5 Page 7230 A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: All Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - DATA LINK COMMUNICATIONS Begin the diagnosis of the data link communications by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure within the Data Link Communications section when a communication malfunction is present. Page 6171 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 12941 Registered And Non-Registered Trademarks Part 4 Window Regulator Replacement - Rear Door (TrailBlazer EXT, Envoy XL) Rear Door Window Regulator: Service and Repair Window Regulator Replacement - Rear Door (TrailBlazer EXT, Envoy XL) Window Regulator Replacement - Rear Door (Trailblazer EXT, Envoy XL) Removal Procedure 1. Lower the window to the midway point (1), if possible. 2. Remove the rear door trim panel. 3. Remove the water deflector. 4. Loosen the regulator glass carrier bolts (2). 5. Slide the window to the full up position and tape it to the window frame. 6. Disconnect the electrical connector from the window regulator motor. 7. Disconnect the retainer (4) securing the regulator cable to the door. 8. Remove the 2 lower regulator retaining bolts (2,3). 9. Loosen the top regulator retaining bolt (1). Important: If the regulator assembly will not operate, removing the top regulator retaining bolt (1) completely will allow the regulator to be removed. 10. Remove the window regulator, lifting up and out from the keyhole slot (5) on the rear door inner panel and through the access hole. Installation Procedure 1. Install the regulator to the door through the access hole. Page 4758 when reinstalling the fuel sender assembly. IMPORTANT: The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm. 2. Install the fuel sender assembly into the fuel tank. NOTE: Refer to Fastener Notice in Service Precautions. 3. Use the J 44402 to install the fuel sender assembly retaining ring. 4. Install the fuel tank. Page 13297 Oil Pressure Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 4306 Body Control Module (BCM) C3 Part 2 OnStar(R) - Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 867 Abbreviations And Meanings Part 12 Page 11677 9. Remove the handle from the roof panel. 10. Partially lower the headliner in order to expose the front handle retaining tab (1). 11. Insert the tip of a flat bladed tool into the front retaining tab (1). 12. With the retaining tab (1) released, pull down on the handle in order to release the roof panel tab (2) from the bezel. 13. Remove the handle from the roof panel. 14. Rotate the bezels in order to release the bezel retaining tabs. 15. Remove the bezels from the headliner. Installation Procedure 1. Position the bezels to the headliner. 2. Rotate the bezels in order to seat the bezel retaining tabs above the headliner. 3. Install the front and rear roof panel tabs into the bezels. Instruments - IPC Odometer Programming Reference Guide Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Page 12686 Disclaimer Page 13920 Various symbols in order to describe different service operations. Page 10722 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 341 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 11986 Disclaimer Page 10211 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 10808 Trailer Connector Page 2960 Registered And Non-Registered Trademarks Part 6 Page 3682 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Heated Oxygen Sensor (HO2S) 2 Heated Oxygen Sensor (HO2S) 2 Page 6931 Application Table Part 1 Page 11092 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Opening Weatherstrip Replacement - Front Door Opening Removal Procedure 1. Remove the front door sill plate. 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. Page 2580 First and second design balancers hubs are shown to assist the technician with proper identification of parts. First design balancers that need to be replaced should be replaced with the second design balancer and the appropriate seal. Parts Information Parts are currently from GMSPO. Disclaimer Page 12410 2. Install the seat switches to the switch bezel, verifying that the retaining tabs are fully seated. 3. Install the switch bezel to the seat with the 3 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the front seat switch bezel screws to 3 N.m (26 lb in). Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the switch bezel assembly from the seat assembly. 2. Remove the buttons from the switch. 3. Release the tabs that retain the seat switch to the seat bezel assembly. 4. Disconnect the electrical connector from the switch. 5. Remove the seat switch from the seat bezel assembly. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. Page 8041 Tires: Technical Service Bulletins Tires - Correct Inflation Pressure Information INFORMATION Bulletin No.: 00-00-90-002J Date: January 28, 2009 Subject: Information on Proper Tire Pressure Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3, H3T 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and clarify additional information. Please discard Corporate Bulletin Number 00-00-90-002I (Section 00 - General Information). Important: ^ Adjustment of tire pressure for a customer with a Low Tire Pressure Monitor (TPM) light on and no codes in the TPM system is NOT a warrantable repair. Claims to simply adjust the tire pressure will be rejected. ^ ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on the vehicle's tire placard (on driver's door) during the PRE-DELIVERY INSPECTION (PDI). Recommended inflation pressure is not the pressure printed on tire sidewall. ^ Tires may be over-inflated from the assembly plant due to the mounting process. ^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure change. ^ 2008-2009 HUMMER H2 Only - The H2 comes standard with Light Truck "D" Load Range tires with a recommended cold inflation pressure of 289 kPa (42 psi). These tires will alert the driver to a low pressure situation at roughly 262 kPa (38 psi) due to a requirement in FMVSS 138 which specifies a Minimum Activation Pressure for each tire type. This creates a relatively narrow window of "usable" pressure values and the warning will be more sensitive to outside temperature changes during the colder months. As with other cold temperature/tire pressure issues, there is nothing wrong with the system itself. If a vehicle is brought in with this concern, check for tire damage and set all tires to the Recommended Cold Inflation Pressure shown on the vehicle placard. Accurate tire pressures ensure the safe handling and appropriate ride characteristics of GM cars and trucks. It is critical that the tire pressure be adjusted to the specifications on the vehicle¡C■s tire placard during PDI. Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure. The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct pressures. The recommended tire inflation pressure is listed on the vehicle¡C■s tire placard. The tire placard is located on the driver¡C■s side front or rear door edge, center pillar, or the rear compartment lid. Tip ^ Generally a 5.6°C (10°F) temperature increase will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure increase. ^ The definition of a "cold" tire is one that has been sitting for at least 3 hours, or driven no more than 1.6 km (1 mi). ^ On extremely cold days, if the vehicle has been indoors, it may be necessary to compensate for the low external temperature by adding additional air to the tire during PDI. ^ During cold weather, the Tire Pressure Monitor (TPM) indicator light (a yellow horseshoe with an exclamation point) may illuminate. If this indicator turns off after the tires warm up (reach operating temperature), the tire pressure should be reset to placard pressure at the cold temperature. ^ The TPM system will work correctly with nitrogen in tires. ^ The TPM system is compatible with the GM Vehicle Care Tire Sealant but may not be with other commercially available sealants. Important: ^ Do not use the tire pressure indicated on the tire itself as a guide. Page 3338 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Page 10858 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 2605 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic converter. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Page 1332 Door Switch: Diagrams Miniwedge (Door Jamb Switch) - LF Page 13427 For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a Campaign Initiation Detail Report. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Page 11768 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 5377 7. Remove the transmission jack. 8. Install the clip (2) that holds the cooler lines together. 9. install the cooler lines to the retainer (1) located on the right side of the engine. 10. Install the front sections of the cooler lines to the vehicle. 11. Install the cooler lines to the retainer (1) located on the radiator shroud. 12. Connect the front and rear cooler lines at the quick connect fitting (2). 13. Install the transmission cooler lines to the radiator. 14. Remove the drain pan from under the vehicle. 15. Lower the vehicle. 16. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. A/C - Intermittently Inoperative/Poor Performance Control Module HVAC: Customer Interest A/C - Intermittently Inoperative/Poor Performance Bulletin No.: 02-01-39-005A Date: August 17, 2005 TECHNICAL Subject: HVAC System Inoperative For A Drive Cycle, Poor HVAC System Performance In High Ambient Temperatures (Update HVAC Control Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to correct the RPO usage information below: RPO CJ2 = HVAC System Air Conditioner Front, Automatic Temperature Control, Auxiliary Temperature Control RPO CJ3 = HVAC System Air Conditioner Front, Manual Temperature Control, Auxiliary Temperature Control Please discard Corporate Bulletin Number 02-01-39-005 (Section 01 - HVAC). Condition Some customers may comment about no cold air from the heating, ventilation and air conditioning (HVAC) system during a drive cycle. This concern may occur at any time during the drive cycle and at any temperature setting. The HVAC system operation returns to normal after the vehicle has been keyed to off and restarted. This concern is intermittent and most likely to occur on hot days. This concern may be found on vehicles equipped with manual (CJ3) and automatic (CJ2) HVAC systems. Other customers may comment about poor HVAC system performance in high ambient temperature conditions. This concern may be present in automatic (CJ2) HVAC systems only. An HVAC control module software update was put into all production vehicles beginning in September 2002. Vehicles built in September 2002 and earlier may need this software update. Correction Update the HVAC control module using software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. This software update addresses both the intermittent no cooling and the poor performance concerns. If the software update does not correct the concerns, perform the HVAC Diagnostic System Check and repair as necessary. If the HVAC control module is replaced with a part from GMSPO, make sure the module has the latest software update. The module may need to be updated even though it is a new part. Warranty Information Disclaimer Page 9486 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Locations Park Neutral Position (PNP) Switch Page 2148 Refrigerant: Service Precautions DETECTOR PRECAUTION CAUTION: Do not operate the detector in a combustible atmosphere since its sensor operates at high temperatures or personal injury and/or damage to the equipment may result. REFRIGERANT R-134A PRECAUTION CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Page 3991 Crankshaft Position (CKP) Sensor Page 9010 6. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 7. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 8. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 9. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. 10. Install the SIR fuse to the fuse block (1) located in the underhood electrical center. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition. Page 10353 Abbreviations And Meanings Part 6 Page 3263 Fan Clutch: Service and Repair Fan Clutch Replacement Removal Procedure 1. Remove the cooling fan and shroud. Refer to: See: Fan Shroud/Service and Repair 2. Remove the fan cllutch from the fan shroud. 3. Remove the bolts retaining the fan blade to the fan clutch. 4. Separate the fan blade from the fan clutch. Installation Procedure 1. Assemble the fan to the fan clutch. Page 11136 Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown this bulletin). Dealer Recall Responsibility - For US (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Page 10361 Abbreviations And Meanings Part 14 Page 816 Page 7265 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 13317 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the grille. 3. Remove the headlamp wire harness from the retaining clip (1). 4. Raise and support the headlamp wire harness (1) to gain access to the front end sensor. Page 4919 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 11636 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 6. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. 5. Access the I/P module connector through the glove box. Page 2379 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 7295 Registered And Non-Registered Trademarks Part 5 A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: All Technical Service Bulletins A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Page 10754 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 10400 Alarm Module: Service and Repair THEFT DETERRENT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. CAUTION: SIR Caution 2. Remove the trim covers. 3. Remove the wire harness straps from the wire harness. 4. Disconnect the connector from the theft deterrent control module. 5. Remove the theft deterrent control module. INSTALLATION PROCEDURE 1. Install the theft deterrent control module. 2. Connect the connector from the theft deterrent control module. 3. Install new wire harness straps to the wire harness assembly. 4. Install the trim covers. 5. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Page 13833 Turn Signal Flasher: Diagrams Turn Signal/Hazard Flasher Module Part 1 Page 10964 Front Bumper Reinforcement: Service and Repair Impact Bar Replacement - Front Bumper Removal Procedure 1. Remove the front fascia. 2. Remove the bolts (1) that retain the fascia support rods (2) to the impact bar (5). 3. Remove the fascia support rods from the impact bar. 4. Remove the bolts (1) that retain the impact bar to the frame (2). 5. Remove the impact bar (3) from the frame. 6. Remove the tow hooks from the impact bar. Installation Procedure 1. Install the tow hooks to the impact bar. 2. Position the impact bar (3) to the frame (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts (1) that retain the impact bar to the frame. Tighten the bolts to 85 N.m (63 lb ft). Page 12412 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the switch bezel assembly from the seat assembly. 2. Remove the buttons from the switch. 3. Release the tabs that retain the seat switch to the seat bezel assembly. 4. Disconnect the electrical connector from the switch. 5. Remove the seat switch from the seat bezel assembly. Installation Procedure 1. Connect the electrical connector to the switch. 2. Install the seat switch to the seat bezel assembly. Verify that the retaining tabs are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Page 10630 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 6763 Starter Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 6375 Submit a Product Recall Claim with the information shown CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter shown. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Page 4574 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Page 12953 Page 9543 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 12321 3. Pull the seat back cover and the seat back pad up high enough to expose the head restraint guides. Refer to Seat Back Cover and Pad Replacement - Front. 4. Squeeze the retaining tabs located at the bottom of the guides together in order to remove the guides from the seat frame. 5. Remove the guides from the seat back frame. INSTALLATION PROCEDURE 1. Install the guides to the seat back frame, verifying that the lower retainers are fully seated to the frame. 2. Install the guide with the locking tab (1) on the seat's right-hand side. 3. Install the seat back cover and pad. 4. Install the front seat head restraint. Page 6275 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove the brake fluid with appropriate tool to the midway point before proceeding. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Compress the front brake caliper piston. 6.1. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. 6.2. Slowly tighten the C-clamp until the piston pushes into the brake caliper enough to slide the brake caliper off the rotor. 6.3. Remove the C-clamp from the brake caliper. 7. Remove the upper brake caliper mounting bolt. 8. Rotate the rear brake caliper downward until it stops. Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Locations Electronic Components Page 8938 Keyless Entry - System Inoperative Door Module: All Technical Service Bulletins Keyless Entry - System Inoperative Bulletin No.: 03-08-52-002 Date: March 27, 2003 TECHNICAL Subject: Remote Keyless Entry Inoperative (Reprogram Liftgate Module) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the Remote Keyless Entry (RKE) is inoperative at times. Cause An anomaly has been identified with the software in the Liftgate Module (RKE functions). The Liftgate Module software is affected when the temperature is approximately 40°C (104°F). Correction Using normal SPS reprogramming procedures, reprogram the LGM Liftgate module. The information was released on TIS version 2.75 or newer broadcast in March 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9654 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 3808 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 8743 18. Disconnect the J 43600 ACR 2000 Air Conditioning Service Center. 19. Remove the fender covers and close the hood. Parts Information Important: Only a small quantity of parts are available. Please DO NOT order for stock only. Parts are currently available from GMSPO. Warranty Information Disclaimer Page 9907 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 10870 Abbreviations And Meanings Part 6 Page 2002 8. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 5143 Torque Converter Clutch Solenoid: Diagrams Torque Converter Clutch Pulse Width Modulated (TGC PWM) Solenoid Valve Connector, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 9981 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 10194 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 835 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 3479 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 8217 Mode Actuator-Auxiliary (Body Type VIN 6) Page 12878 Brake Warning Indicator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 551 Page 6838 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 1327 Windshield Wiper/Washer Switch (Turn Signal/Multifunction Switch C3) Page 927 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 9011 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 9414 Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: All Technical Service Bulletins Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 11157 3. Using the line from the china marker (4) as a guide and starting at the sill plate, install the seal along the rear rocker panel with seal bulb (2) toward the door. Flatten the bulb and align it to the china marker line pressing lightly. 4. Close the door and check for the gasket pushing out between the door and the body. 5. If the gasket was pushing out, realign the gasket in that area. 6. Trim the gasket so that it does not extend higher than the rocker panel (5) as necessary. 7. When the gasket is located, open the door and firmly press the gasket into place. A roller tool may be helpful in seating the gasket. 8. Check the door latch for proper operation: 8.1. Open the rear door. 8.2. Open the rear side closure. 8.3. Listen for two audible clicks while rotating the fork bolt from the full open to the fully latched position. 9. If two distinct audible clicks are NOT heard: Page 58 Abbreviations And Meanings Part 3 Page 12958 Page 10493 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 13237 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 7320 Application Table Part 2 Page 10495 Page 10040 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 6957 Fuse Block - Rear C2 Part 5 Page 259 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 6750 Page 9906 Page 768 1. Remove the 2 screws that retain the insulator panel to the instrument panel (I/P). 2. Release the insulator panel retaining clip from the I/P substrate. 3. Lower the insulator panel. 4. Remove the flasher retaining bracket from the insulator panel. 5. Disconnect the flasher from the electrical connector. 6. Remove the flasher from the vehicle. 7. Position the new flasher to the insulator panel. 8. Connect the electrical connector to the flasher. 9. Install the flasher retaining bracket to the insulator panel. 10. Install the insulator panel tabs to the cowl slots. 11. Raise the insulator panel to the I/P. 12. Install the insulator panel retaining clip to the I/P substrate. 13. Install the 2 screws that retain the insulator panel to the I/P. Tighten Tighten the screws to 2.5 N.m (22 lb in). Page 5503 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Page 9310 Cellular Phone Microphone: Description and Operation ONSTAR(R) MICROPHONE The OnStar(R), or cellular, microphone can be part of the rearview mirror assembly, or on some vehicle lines, can be a separate, stand alone unit. In either case, the microphone is supplied voltage on the cellular microphone signal circuit, while voice data from the user is sent back to the VCIM by means of either a cellular microphone low reference circuit or a drain wire. Page 9258 6. Connect the coaxial cable (1) to the inner antenna coupling. Service and Repair Power Steering Fluid Cooler: Service and Repair Power Steering Cooler Replacement Removal Procedure 1. Remove the radiator air intake baffle. 2. Install a drain pan under the vehicle. 3. Disconnect the power steering hose assembly from the power steering cooler. 4. Remove the power steering cooler mounting bolts. 5. Remove the power steering cooler from the radiator support. Installation Procedure Page 13047 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the LF door trim panel. 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. Page 4796 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. 1. Install the CKP sensor into the engine block. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 4076 Page 10525 Page 7253 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 4526 Steps 8-9 Page 8380 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 908 7. Install the rear electrical center cover. 8. If replacing the BCM on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 9. If replacing the BCM on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 10. Connect the negative battery cable. 11. If installing a replacement BCM, program the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Body Wiring Harness Extension Replacement - BCM BODY WIRING HARNESS EXTENSION REPLACEMENT - BCM REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the body wiring harness extension on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the body wiring harness extension on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. Page 7180 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 2670 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement Removal Procedure 1. Remove the drivebelt. 2. Inspect the drivebelt. Change the drivebelt as necessary. 3. Using a wrench loosen and remove the drivebelt tensioner bolt. 4. Remove the drivebelt tensioner. Installation Procedure 1. Install the drive belt tensioner. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the drive belt tensioner bolt. Tighten the drive belt tensioner bolt to 50 Nm (37 ft. lbs.). 3. Install the drive belt Drive Belt Replacement. Page 5099 Disclaimer Page 5844 Tighten the nut in small increments, as needed, until the rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft. 11. Install the brake rotors. 12. Install the brake calipers. 13. Install the tire and wheel assemblies. 14. Inspect and add axle lubricant to the axle housing, if necessary. Page 4638 3. This step applies to Bartholomew style connectors ONLY. Squeeze the plastic quick connect fitting release tabs. 4. This step applies to Q Release style connectors ONLY. Release the fitting by Pushing the tab toward the other side of the slot in the fitting. 5. This step applies to Squeeze to Release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick connect fitting. 6. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab doesn't move try pressing the tab in from the opposite side. The tab will only move in one direction Page 11283 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 9168 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Diagrams Driver Door Lock Cylinder Switch - LF Page 7612 Alignment: Service and Repair Wheel Alignment Measuring Procedures Inspection and Preparation Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Irregular or premature wear ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. ^ Inspect the vehicle trim height. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Alignment Angle Measurement Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 4945 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 10958 Front Bumper Cover / Fascia: Service and Repair Fascia Replacement - Front Bumper (Chevrolet, GMC) Removal Procedure 1. Remove the grille. 2. Remove the 2 bolts that retains the top of the fascia to the headlamp panel assembly. 3. Remove the push-pin that retains the top of the fascia to the headlamp panel assembly. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the push-pins (3) that retain the fascia to the fascia support rods (2). 6. Remove the fog lamps from the fascia. 7. Remove the cornering lamps from the fascia. 8. Remove the air deflector. 9. Remove the 4 push-pins that retain the bottom of the fascia to the headlamp panel assembly. 10. Release the body side attachment tabs and pull the fascia straight forward from the wheelhouse opening in order to remove the fascia from the vehicle. Installation Procedure Page 7250 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 13026 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 4716 3. Remove the fuel fill pipe bracket nut (2). 4. Raise and suitably support the vehicle. 5. Remove the fuel fill pipe ground strap bolt. 6. Cut off the ground strap ring terminal and tie strap. 7. Loosen the fuel hose clamp (8). 8. Remove the fuel fill upper pipe (7) from the vehicle. 9. Install the new fuel fill upper pipe into the vehicle. Use P/N 88983256 for 2002-2003 model year vehicles or P/N 15131043 for 2004 model year vehicles. 10. Tighten the fuel hose clamp. Tighten Tighten the clamp to 2.5 N.m (22 lb in). 11. Wrap the excess length of ground strap around the fuel hose as necessary. 12. Install the fuel fill pipe ground strap bolt in its original location. 13. Loosen the fuel hose clamps (1, 3). 14. Remove the lower fuel hose (2) from the vehicle. 15. Install the new lower fuel hose into the vehicle. 16. Tighten the lower fuel hose clamps. Tighten CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. The scan tool instructs you to perform the following items: - Accelerate to wide open throttle (WOT). - Release the throttle when fuel cut-off occurs. - Observe the fuel cut-off for the engine that you are performing the learn procedure on. - The engine should not accelerate beyond calibrated RPM value. - Release the throttle immediately if value is exceeded. - Block the drive wheels. - Set the parking brake. - DO NOT apply the brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn the A/C OFF. - The vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. With the scan tool, enable the crankshaft position system variation learn procedure. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release the throttle when the fuel cut-off occurs. 8. The scan tool displays Learn Status-Learned this ignition: - If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. - If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. - If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The crankshaft position system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P1336 sets: Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - Crankshaft position sensor replacement - Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Page 2835 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 13128 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Locations Body Control Module: Locations Body Wiring Harness Extension Harness Page 970 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 8. CAUTION: Refer to SIR Caution in Service Precautions. 2. Remove the floor console. 3. Partially remove the console mounting bracket in order to allow access to the rear carpet. Refer to Bracket Replacement - Console Floor in Instrument Panel, Gages, and Console. 4. Position the rear carpet in order to access the sensing and diagnostic module (SDM). 5. Disconnect the electrical connectors (2) from the SDM (1). 6. Remove the nuts that retain the SDM to the floor panel. 7. Remove the SDM from the vehicle. Installation Procedure Specifications Compression Check: Specifications Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. Page 6111 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) C2 Electronic Brake Control Module (EBCM) C2 Part 1 of 2 Page 8937 Inflatable Restraint Electronic Frontal Sensor Page 6873 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 1002 32. Install the new hose (1), # 1005 (L6 engine) or# 1006 (V8 engine) onto the coolant bypass valve at the location the above hose was removed. The other end of this hose will be installed on the auxiliary heater pump outlet port. Specifications Idle Speed: Specifications Engine Speed ...................................................................................................................................... .......................................................... 500 - 700 RPM Desired Idle Speed .............................................................................................................................. ........................................................ PCM Controlled Page 7018 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 2471 Do NOT attach the positive jumper cable to the stud located under the engine compartment fuse block cover. Doing so may blow the fuse resulting in various interior electrical system conditions. Disclaimer Page 8752 Forward Lamp Harness, Right Side Page 10175 Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 8038 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Page 5011 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 5732 Left Side Control Valve Body Assembly General Overview Page 11035 16. Refinish as necessary. 17. Install and align all of the related panels and components. Page 767 this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT RECALL CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the Claim Form provided to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. All recall reimbursement questions should be directed to the following number: 1-800-204-0261. Disclaimer Service Procedure Page 6632 Page 10919 10. With an upward motion, disconnect the body wiring extension (1) from the rear electrical center. 11. Remove the body wiring extension from the vehicle. INSTALLATION PROCEDURE 1. Using a downward motion, install the body wiring extension (1) to the rear electrical center. IMPORTANT: Ensure the sliding latch is fully extended before connecting the body wiring extension to the rear electrical center. Page 10854 Various symbols in order to describe different service operations. Page 12403 Seat Adjuster Switch - Passenger (w/o Heat) Part 1 Page 4770 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 7478 C304 Part 2 Page 10328 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 11690 8. Pull the sunshade downward while maintaining outboard pressure to the sunshade. You will notice a separation between the headliner and the sunshade bezel. 9. In order to remove the sunshade from the headliner, carefully grab the headliner at the windshield pillar area and apply downward pressure while gently rocking the sunshade up and down. 10. Remove the inboard retainer screw. 11. Remove the inboard retainer (1) from the headliner. 12. If the vehicle is equipped with lighted sunshades, perform the following steps: 12.1. Reach above the headliner to access the electrical connector (1). 12.2. Remove the electrical connectors from the headliner substrate. 12.3. Disconnect the sunshade electrical connector from the headliner harness. 13. Remove the sunshade from the vehicle. INSTALLATION PROCEDURE 1. If the vehicle is equipped with lighted sunshades, perform steps 2 through 8: Page 11083 Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) Page 7157 Relay Box: Service and Repair Rear Electrical Center or Junction Block Replacement REAR ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a cargo position. 4. Remove the rear electrical center cover. 5. Remove the battery feed terminal nut (2) from the junction block. 6. Remove the body control module (BCM) from the rear electrical center. 7. Fully loosen the 3 bolts (1) that retain the junction block to the electrical connectors. Page 9187 Abbreviations And Meanings Part 20 Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: All Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 1214 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield. 3. Remove the electrical connector from the oil pressure switch. 4. Remove the oil pressure switch. Installation Procedure NOTICE: Refer to Fastener Notice in Service Precautions. See: Engine, Cooling and Exhaust/Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the oil pressure switch. Tighten the oil pressure switch to 20 Nm (15 ft. lbs.). 2. Install the electrical connector to the oil pressure switch. 3. Install the engine shield. 4. Lower the vehicle. Page 1024 For vehicles repaired under warranty, use the table. Disclaimer Page 7870 Page 9470 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 6218 Abbreviations And Meanings Part 17 Page 2167 22. Close the J29532, or equivalent, fluid tank valve, then disconnect the J29532, or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II00, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Service and Repair Accumulator HVAC: Service and Repair ACCUMULATOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Disconnect the electrical connector from the A/C pressure switch. 3. Remove the A/C low pressure switch. 4. Remove the nut (3) retaining the accumulator (4) to evaporator (1). 5. Remove the compressor suction hose assembly from the accumulator. 6. Remove and discard the O-ring seals. 7. Remove the accumulator clamp nut. 8. Remove the accumulator from the vehicle. INSTALLATION PROCEDURE 1. Install the accumulator to the vehicle. IMPORTANT: If replacing the accumulator, add the refrigerant oil to the accumulator. Refer to Refrigerant System Capacities for the capacity information. 2. Install the accumulator into the accumulator clamp. 3. Install the accumulator clamp nut. Tighten the nut to 10 N.m (88 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the A/C low pressure switch. Tighten the A/C low pressure switch to 5 N.m (44 lb in). 5. Install new O-ring seals. 6. Install the accumulator to the evaporator. 7. Install the accumulator retaining nut. Tighten the nut to 28 N.m (21 lb ft). 8. Connect the compressor suction hose to the accumulator (4). 9. Install the suction hose nut. Tighten the nut to 48 N.m (35 lb ft). Page 6286 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Page 13404 Page 7601 Frame Angle Measurement (Express / Savana Only) ........ Page 320 A/C - Musty Odors On Start Up Control Module HVAC: All Technical Service Bulletins A/C - Musty Odors On Start Up Bulletin No.: 05-01-39-002A Date: March 17, 2006 TECHNICAL Subject: Musty Odor from HVAC System (Reprogram HVAC Control Module to Enable Afterblow Function) Models: 2004-2006 Buick Rainier 2003-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2003-2004 Oldsmobile Bravada with Automatic Temperature Control HVAC System (RPO CJ2) Supercede: This bulletin is being revised to add the 2006 model year and update the calibration release date. Please discard Corporate Bulletin Number 05-01-39-002 (Section 01 - HVAC). Condition Some customers may comment on a musty odor from the Heating, Ventilation and Air Conditioning (HVAC) system. This condition occurs most often on initial start up after the vehicle was driven on a hot humid day. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. Correction Important: The afterblow function should not be enabled until after the purpose and operation of it is explained to your customer and they approve of the change. Once the afterblow function is enabled there are no calibrations currently released to disable it. Technicians are to reprogram the HVAC Control Module with an updated software calibration that will enable the afterblow function. The new calibration will be released beginning with TIS satellite data update version 2.0, which was made available February 5, 2006. The blower motor will turn on approximately 10 minutes after the vehicle is shut off. The blower motor will run continuously for 10 minutes at a 30% duty cycle. The afterblow function will only activate if the air conditioning compressor was engaged during conditions of high ambient temperature. If the vehicle is started within 10 minutes of the last key off, the afterblow function from the previous key cycle will be cancelled. Technicians should not attempt to reprogram a vehicle with a Manual Temperature Control HVAC system (RPO CJ3). Technicians should perform this HVAC Control Module reprogram instead of installing the Electronic Evaporator Dryer Module Kit referred to in the Air Conditioning Odor bulletin, Corporate Bulletin Number 99-01-39-004A. Warranty Information Recall 05V198000: Flasher Module Replacement Turn Signal Flasher: All Technical Service Bulletins Recall 05V198000: Flasher Module Replacement MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2004 Chevrolet/Trailblazer 2003-2004 GMC/Envoy 2003-2004 Isuzu/Ascender 2003-2004 Oldsmobile/Bravada 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V198000 RECALL DATE: April 29, 2005 COMPONENT: Exterior Lighting: Turn Signal POTENTIAL NUMBER OF UNITS AFFECTED: 286478 SUMMARY: On certain trucks and sport utility vehicles, the driver wishing to signal a turn by moving the directional signal lever, (up or down) may cause the front marker/turn lights and rear turn lights to flash in a manner similar to hazard warning, rather than flashing on the desired side only. CONSEQUENCE: The driver may not be able to clearly signal their intentions to turn, change travel lanes, or potentially warn others of an impaired vehicle operating condition increasing the risk of a crash. REMEDY: Dealers will replace the suspect flasher modules with a new flasher module designed with sealed relays and more durable contact material inside of the relays. The recall is expected to begin during August 2005. owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727, Buick at 1-866-608-8080, and Oldsmobile at 1-800-630-6537. NOTES: GM recall No. 05044. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Page 11239 IMPORTANT: In any area damaged beyond recognition, space the plug weld holes every 40 mm (1 1/2 in.) apart. 1. Drill 8 mm (5/16 in.) plug weld holes in the service part as necessary in the locations noted from the original part. 2. Prepare all of the attachment surfaces as necessary. 3. Apply a weld-thru primer to all of the bare metal surfaces. 4. Position the hinge bracket. 5. Plug weld accordingly. 6. Clean and prepare all of the welded surfaces. IMPORTANT: Prior to refinishing, refer to publication GM4901M-D-01 GM Approved Refinish Materials for recommended products. Do not combine the paint systems. Refer to the paint manufacturer's recommendation. 7. Apply sound deadening materials. 8. Apply an approved anti-corrosion primer. Page 4168 Steps 2-5 Page 514 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Locations Engine, Left Side Page 12904 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 8838 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 11712 1. Starting at the top of the garnish molding, carefully release the upper attaching clip that retains the garnish molding to the first pillar. 2. Release the remaining 2 retaining clips from the first pillar. 3. Remove the garnish molding (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the garnish molding (1) to the vehicle. 2. Align the locating fingers to the corresponding holes in first pillar. 3. Starting at the top of the garnish molding, seat the attachment clips that retain the garnish molding to the first pillar. Garnish Molding Replacement - Body Side Window - Front (TrailBlazer EXT, Envoy XL) Garnish Molding Replacement - Body Side Window - Front (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the bolt that retains the seat belt upper anchor to the body. 2. Remove the garnish molding from the vehicle. Page 10187 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 1325 Turn Signal/Multifunction Swtich C3 Page 13054 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the EFS connectors to both (2) EFS's. 3. Install the CPAs to both EFS connectors. 4. Install sensor bracket to bumper. 5. Install the grille. 6. Install the SIR fuse into the fuse block (1) located in the underhood fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 1. Remove the key from the ignition. Page 11078 Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. Recall - Spark Plug Misfire Condition Spark Plug: Recalls Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the A/T, Exhaust - Rattling Noise From Under the Vehicle Transmission Cooler: All Technical Service Bulletins A/T, Exhaust - Rattling Noise From Under the Vehicle Bulletin No.: 04-07-30-002 Date: January 20, 2004 TECHNICAL Subject: Rattle Type Noise Coming From Under the Vehicle (Reposition Transmission Oil Cooler Lines) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on a rattle type noise coming from under the vehicle. Cause This condition may be caused by one of the transmission oil cooler lines contacting the exhaust catalytic converter. Correction Raise the vehicle and carefully reposition the transmission oil cooler line(s) to provide 10 mm (0.393 in) clearance between the exhaust catalytic converter and the line. Replace the transmission oil cooler line if any damage is present. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Page 11602 1. Position the carpet to the floor panel. 2. Raise the rear portion of the floor console bracket and slide the carpet underneath the console bracket. 3. Position the rear carpet over the edge of the front carpet. 4. Align the holes in the carpet to the seat studs on the floor panel. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the four nuts (2) retaining the rear of the floor console bracket to the floor weld studs. Tighten the nuts to 25 N.m (18 lb ft). 6. Feed the bussed electrical center base and the communication interface module electrical connectors through the pass through holes in the carpet. 7. Install the floor console. 8. Install the center pillar trim panels. 9. Install the front side door sill plates. 10. Pass the communication interface module electrical connectors through the small hole in the carpet. 11. Pass the body electrical block electrical connectors through the small hole in the carpet. 12. Install the body electrical block. 13. Install the carpet ensuring that the carpet hooks over the left wheelhouse panel stud. 14. Install the nut (1) securing the stowage jack carrier to the wheelhouse panel. 15. Install the right rear quarter lower trim panel. 16. Install the left rear quarter lower trim panel. 17. Install the left/right rear body side trim rear window garnish molding. 18. Install the left/right front body side window garnish molding 19. Install the lift gate door sill plate. 20. Install the cargo tie-down loops and secure the loops with the tie-down bolts. Page 1734 English Prevailing Torque Fastener Minimum Torque Development Part 1 Left Engine Mount: Service and Repair Left Engine Mount and Bracket Replacement- Left Tools Required - J 41240 Fan Clutch Remover and Installer Removal Procedure 1. Disconnect the negative battery cable. 2. Using the J 41240 to secure the water pump pulley, loosen the cooling fan hub nut from the water pump shaft. 3. Remove the MAP sensor electrical connector and the retainer (1). 4. Remove the MAP sensor (2). 5. Remove the left shock module (if frame mount is being removed). Page 9152 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 9666 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 1580 For vehicles repaired under warranty, use the table. Disclaimer Page 6667 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 471 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 4203 Exhaust Pipe Page 8802 Air Temperature Sensor-Upper Lift Page 10484 Page 11573 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Page 2750 10. Clip transmission cooler lines to block. 11. Connect prop shaft to front differential. 12. Install the steering gear crossmember. 13. Install the left and right wheel drive shaft. 14. Install the oil pan drain plug. Torque the oil pan drain plug to 26 Nm (19 ft. lbs.). 15. Install the engine protection shield and secure with the bolts. Tighten the engine protection shield bolts to 25 Nm (18 ft. lbs.). 16. Install the left and the right front tires. 17. Lower the vehicle. Important: Inspect the engine for oil leaks in order to ensure all sealing surfaces are sealed. 18. Service the engine with oil. Page 9797 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 1110 Position Sensor - Horizontal Motor (w/Memory) Page 6204 Abbreviations And Meanings Part 3 Page 6205 Abbreviations And Meanings Part 4 Page 1691 Page 943 Powertrain Control Module (PCM) C1 Part 3 Page 12825 Abbreviations And Meanings Part 2 Page 12492 Page 9433 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Specifications Oil Pressure Sensor: Specifications Oil Pressure Sensor 15 ft. lbs. Page 9186 Abbreviations And Meanings Part 19 Page 8753 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch (w/Manual - HVAC System) Page 7409 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Restraints - Seat Belt Retractor Jamming Prevention Seat Belt Retractor: Technical Service Bulletins Restraints - Seat Belt Retractor Jamming Prevention Bulletin No.: 03-09-40-006B Date: December 02, 2005 INFORMATION Subject: Information on Avoiding Front Seat Belt Retractor Jamming When Storing Seat Belt Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add the 2006 model year and Saab 9-7X models. Please discard Corporate Bulletin Number 03-09-40-006A (Section 09 - Restraints). This bulletin is being issued to provide information to the customers if they comment that the left or right front seat belt may appear to not release from the retractor when trying to put on the seat belt. A Description For Your Customer This condition generally does not require replacement of any parts. This condition is the result of allowing the belt to enter the retractor at a high rate of speed. If the belt is allowed to go all the way back into the retractor very quickly, it is possible that the force of the belt stopping suddenly against the seat back will vibrate the retractor. This vibration "fools" the retractor into thinking that the vehicle is changing velocity. The normal function of the retractor under this condition is to lock the belt. How to Correct or Eliminate the Condition The only way to completely eliminate the condition is not to allow the belt to retract back all the way into the retractor quickly. The fast retraction usually occurs when the customer holds the latch while unbuckling and guides the webbing into the retractor quickly until it's fully stowed. As long as the customer guides the belt at a slower rate of speed, the retractor will work consistently without locking. Also, if the customer unbuckles the belt and lets the webbing retract on its own (without guiding it), there is generally enough friction from the belt against clothing to slow down the belt so it won't lock when it fully stows. If the customer does allow the belt and latch plate to retract quickly, the retractor can easily be restored to normal operation. Simply pull on the belt to create some slack in the webbing and pay back some of the webbing into the retractor. Slack can also be created by pushing on the foam at the top of the seat back. After a maximum of 10 mm (0.39 in) of webbing is introduced into the retractor, it will unlock and function again. Please demonstrate this action to your customer. After an explanation and demonstration, most customers should be able to unlock the retractor without a problem. You may give a copy of this bulletin to your customer for further reference. Disclaimer Page 3344 11. Install the lower radiator support shield, if equipped. 12. Lower the vehicle. 13. Fill the cooling system. Weatherstrip Replacement - Auxiliary Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Page 11183 Rear Door Latch: Service and Repair Latch Replacement - Rear Door Removal Procedure 1. Close the window to the full up position. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the inside door handle lock rods from the latch. 5. Disconnect the outside handle lock rod from the outside handle. 6. Remove the 3 fasteners that retain the latch to the door. 7. Disconnect the electrical connectors from the latch. 8. Remove the latch from the door. 9. Remove the actuator from the latch. Installation Procedure 1. Install the actuator to the latch. 2. Position the latch to the door. 3. Connect the electrical connectors to the latch. Page 7259 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 2811 Abbreviations And Meanings Part 9 Page 9661 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 11472 DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Page 1003 33. Install the new hose, # 1003 (L6 engine) or # 1004 (V8 engine) onto the auxiliary heater pump inlet port. Connect the other quick connect end to the engine. Page 12776 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 1134 2. Install the seat switches to the switch bezel, verifying that the retaining tabs are fully seated. 3. Install the switch bezel to the seat with the 3 screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the front seat switch bezel screws to 3 N.m (26 lb in). Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the switch bezel assembly from the seat assembly. 2. Remove the buttons from the switch. 3. Release the tabs that retain the seat switch to the seat bezel assembly. 4. Disconnect the electrical connector from the switch. 5. Remove the seat switch from the seat bezel assembly. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. Page 1959 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: - The drive belt - The drive belt tensioner - The drive belt idler pulley - The crankshaft balancer pulley - The accessory drive component mounting brackets - The accessory drive components + The power steering pump, if belt driven + The generator + The A/C compressor, if equipped + The engine cooling fan, if belt driven + The water pump, if belt driven + The vacuum pump, if equipped + The air compressor, if equipped The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers (chloroprene or EPDM) and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Page 8661 8. Connect the heater hoses to the heater core. 9. Install the nuts to the HVAC module studs. Tighten Tighten the nuts to .....10 N.m (89 lb in). 10. Remove the cap or tape from the A/C lines. 11. Install the new O-ring seals. 12. Install the nuts (3) to the evaporator core studs. Tighten Tighten the nuts to .....20 N.m (15 lb ft). 13. Lower the vehicle. 14. Fill the cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 15. Evacuate and charge the system. 16. Leak test the fitting of the component using the J 39400-A. Page 11474 Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information Page 6940 Fuse: Application and ID Underhood Fuse Block Location View Application Table Part 1 Page 11205 Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 9157 Various symbols in order to describe different service operations. Page 11645 6. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 7. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 8. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 9. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. 10. Install the SIR fuse to the fuse block (1) located in the underhood electrical center. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition. Page 4718 Fuel Filler Hose: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel fill cap. 2. Remove the fuel fill pipe housing. 3. Remove the fuel fill pipe bracket nut (2). 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Page 1270 Forward Lamp Harness, Right Side Page 593 Abbreviations And Meanings Part 5 Page 7461 C104 Part 1 Page 11232 2. Install the top regulator retaining bolt (1) through the keyhole slot (5) in the rear door inner panel. 3. Install the 2 lower regulator retaining bolts (2,3). Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the bolts in the following sequence. 1. Tighten the lower regulator retaining bolt (3) to 10 N.m (89 lb in). 2. Tighten the upper regulator retaining bolt (1) to 10 N.m (89 lb in). 3. Tighten the middle regulator retaining bolt (2) to 10 N.m (89 lb in). 5. Connect the regulator cable retainer (4) on the door. 6. Connect the electrical connector to the rear window regulator motor. 7. Remove the tape and position the rear window to the regulator glass carrier plate. 8. Loosely tighten the regulator glass carrier bolts (2). 9. Operate the window upward to the full up position, ensuring the window remains in the run channels. Tighten the regulator glass carrier bolts (2) to 10 N.m (89 ft 16 in). Install the water deflector. Install the trim panel. Page 6681 Abbreviations And Meanings Part 3 Page 6066 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Page 7630 10. Remove the air spring level sensor to the frame mounting bolts. 11. Remove the air spring level sensor. Installation Procedure 1. Install the air spring level sensor link to the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not remove the air spring level sensor locating pin until the air spring level sensor has been properly aligned and the proper D height has been measured and maintained. 2. Install the air spring level sensor to the frame mounting bolts. Tighten the air spring level sensor to the frame mounting bolts to 8 Nm (6 lb ft). Page 4686 Involved are certain 2004 model year Buick Rainier and GMC Envoy XUV; 2002-2004 model year Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles built within the VIN breakpoints shown above. Parts Information Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement in SI. 2. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement in SI. 3. Replace the fuel sender assembly with the new fuel sender assembly provided in the kit. The kit does not provide a new fuel level sensor. Transfer the fuel level sensor from the old fuel sender assembly onto the new fuel sender assembly. Refer to Fuel Sender Assembly Replacement in SI. 4. Install the fuel tank. Refer to Fuel Tank Replacement in SI. Claim Information For vehicles repaired under the terms of this special coverage, submit a claim with the information shown above. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct this condition are to be submitted to the dealer prior to or by October 31, 2009. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000 km, whichever occurs first. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Locations Headlamp Washer Switch Page 5806 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Grade ................................................................................................................................................... .................................................................... Synthetic Viscosity .......................................................... ......................................................................................................................................................... 75W-90 Description and Operation Traction Control Indicator Lamp: Description and Operation Traction Control Indicators (w/NW7) LOW TRACTION The low traction indicator is part of the traction control switch. The EBCM applies ground to the traction control active signal circuit in order to illuminate the low traction indicator during a traction control event. TRACTION OFF The traction off indicator, which is part of the traction control switch, turns OFF when ground is applied to the service traction control signal circuit. The EBCM illuminates the traction off indicator if any of the following conditions are present. ^ The EBCM inhibits the traction control system. ^ The driver manually disables the traction control system by pressing the traction control switch. ^ The automatic transmission shift lever is in the low (1) position. The EBCM inhibits the traction control system when a TCS-disabling malfunction occurs, or when the automatic engagement feature is programmed to disable the TCS when the ignition is turned ON. Refer to Programming the Traction Control Automatic Engagement Feature. Page 5827 14. Install the pinion yoke. Align the marks made during removal. 15. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 16. Install the washer and a new pinion nut. 17. Install the J8614-01 onto the pinion yoke as shown. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 18. Tighten the pinion nut while holding the J8614-0 1. Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 19. Measure the rotating torque of the pinion using an inch-pound torque wrench. Specification The rotating torque of the pinion should be 1.0 - 2.3 Nm (10 - 20 inch lbs.) for used bearings or 1.7 - 3.4 Nm (15 - 30 inch lbs.) for new bearings. 20. If the rotating torque measurement is below 1.0 Nm (10 inch lbs.) for used bearings, or 1.7 Nm (15 inch lbs.) for new bearings, continue to tighten the pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.0 - 2.3 Nm (10 - 20 inch lbs.) for used bearings or 1.7 - 3.4 Nm (15 - 30 inch lbs.) for new bearings. Page 176 For vehicles repaired under warranty, use the table. Disclaimer Page 6824 Registered And Non-Registered Trademarks Part 2 Page 11062 Front Door Panel: Service and Repair Water Deflector Replacement - Front Door Water Deflector Replacement - Front Door Removal Procedure 1. Remove the door trim panel. 2. Remove the speaker. 3. Remove the outside rear view mirror (ORVM) wire harness from the door. 4. Carefully remove the water deflector from the door by releasing the adhesive backing. Installation Procedure 1. Position the water deflector to the door. 2. Press the water deflector to the door. Ensure that the water deflector forms a proper seal around the surface of the door panel. 3. Install the ORVM wire harness to the door. 4. Install the speaker. 5. Install the door trim panel. Page 13161 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 5398 Fluid Pump: Technical Service Bulletins A/T - 4L60-E Oil Pump Identification Bulletin No.: 03-07-30-056 Date: November 05, 2003 INFORMATION Subject: 4L60-E Automatic Transmission Oil Pump First And Second Design Identification Models: 1997-2002 Chevrolet Camaro 1997-2002 Pontiac Firebird 2002-2004 Cadillac Escalade, Escalade EXT 1997-1999 Chevrolet C/K Full Size Pickup 1997-2004 Chevrolet Astro, Blazer, Corvette, Express, S-10, Suburban 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Tahoe 2002-2004 Chevrolet Avalanche, TrailBlazer 2004 Chevrolet Colorado, SSR 1997-1999 GMC Suburban 1997-2001 GMC Jimmy 1997-2004 GMC Envoy, Safari, Savana, Sierra, Sonoma 1999-2004 GMC Denali 2000-2004 GMC Yukon, Yukon XL 2004 GMC Canyon 1997-2004 Oldsmobile Bravada 2003-2004 HUMMER H2 with 4L60-E Automatic Transmission (RPOs M30, M32, M33) Page 956 Engine Control Module: Description and Operation POWERTRAIN CONTROL MODULE (PCM) The PCM verifies that the password received from the theft deterrent control module via the serial data circuit is correct. The PCM can learn only one fuel continue password. If the fuel continue password is correct, the PCM enables the starting and fuel delivery systems. The PCM disables the starting and fuel delivery systems if any of the following conditions occur: - The fuel continue password is incorrect. - The fuel disable password is sent by the theft deterrent control module. - No passwords are received - there is no communication with the theft deterrent control module. The powertrain control module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. The PCM controls all ignition system functions, and constantly corrects the spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Page 9828 Abbreviations And Meanings Part 20 Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil Level Indicator Tube Stud 89 inch lbs. Page 5336 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Page 11821 Abbreviations And Meanings Part 6 Page 6892 Abbreviations And Meanings Part 7 Page 10825 HVAC System - Manual Low Pressure Sensor / Switch: Description and Operation HVAC System - Manual HVAC SYSTEM - MANUAL A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 12 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 124 kPa (18 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275 kPa (40 psi). This enables the A/C compressor to turn back ON. Weatherstrip Replacement - Auxiliary Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the side doors, right or left side. 2. Remove the push pin retainers from the front door sealing weatherstrip located at the base of the pillar. 3. Pull back the front door sealing weatherstrip in order to expose the weatherstrip side retainer screws. 4. Remove the screws from the weatherstrip side retainer. 5. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer to the windshield pillar. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers to the front door sealing weatherstrip located at the base of the pillar. 4. Close the doors. Page 570 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 3360 Removal Procedure 1. Drain the engine coolant. 2. Reposition the inlet radiator hose clamp (2) at the radiator using J 38185. 3. Remove the inlet radiator hose from the radiator. 4. Reposition the inlet radiator hose clamp (1) at the engine outlet using J 38185. 5. Remove the inlet radiator hose from the engine. Installation Procedure 1. Install the inlet radiator hose clamps (1, 2) to the radiator hose. 2. Install the inlet radiator hose to the engine. 3. Reposition the inlet radiator hose clamp (1) using J 38185. 4. Install the inlet radiator hose to the radiator. 5. Reposition the inlet radiator hose clamp (2) using J 38185. 6. Fill the cooling system. Page 2945 Abbreviations And Meanings Part 17 Page 1888 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the fuel pressure service connection cap. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Install the fuel tank shield if removed. Page 11241 Hood Hinge: Service and Repair Hood Hinge Replacement Hood Hinge Replacement Removal Procedure 1. Remove the hood. 2. Using a grease pencil or other suitable marking device, mark the location of the hinge(s) (3) to the body. 3. Remove the bolts (2) that retain the hinge(s). 4. Remove the hinge(s) from the body. Installation Procedure 1. Position the hinge(s) (3) to the body as previously marked. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (2) that retain the hinge(s) to the body. Tighten the bolts to 25 N.m (18 lb ft). 3. Install the hood. Page 9677 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 2919 Conversion - English/Metric Part 1 Wheel Alignment Specifications Page 2775 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Locations Electronic Components Page 94 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms - Accessory Delay Module SYMPTOMS - ACCESSORY DELAY MODULE IMPORTANT PRELIMINARY CHECKS BEFORE STARTING 1. Perform the Diagnostic System Check - Accessory Delay Module before using the Symptom Tables in order to verify that all of the following are true: There are no DTCs set. - The control module(s) can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Accessory Delay Module 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory power (RAP) Description and Operation. VISUAL/PHYSICAL INSPECTION - Inspect for aftermarket devices which could affect the operation of the Accessory Delay Module system. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout (with Relay)Retained Accessory Power (RAP) On After Timeout (No Relay, Class 2) - Retained Accessory Power (RAP) Inoperative (with relay)Retained Accessory Power (RAP) Inoperative (No Relay Class 2) Diagrams Oil Level Sensor For ECM: Diagrams Engine Oil Level and Temperature Sensor Page 9778 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 2225 Fuse Block - Rear C4 Part 1 Page 10888 Abbreviations And Meanings Part 24 Page 334 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 3049 Steps 16-19 Page 9003 11. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 12. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 13. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 14. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 9 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 11778 Specifications Oil Pump Drive Shaft: Specifications Oil Pump Drive Gear Outer Diameter Tolerance 2.893-2.891 inch Width 0.613-0.611 inch Oil Pump Driven Gear Outer Diameter Tolerance 3.428-3.426 inch Width 0.605-0.611 inch Lobe Inner Diameter - Maximum 0.469 inch Page 1838 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the fuel pressure service connection cap. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Install the fuel tank shield if removed. Page 11829 Abbreviations And Meanings Part 14 Specifications Engine Oil Drain Plug: Specifications Oil Pan Drain Plug 19 ft. lbs. Procedures Trunk / Liftgate Lock Cylinder: Procedures The content of this article/image reflects the changes identified in TSB Bulletin No.: 06-08-66-001 Date: February 14, 2006 SERVICE MANUAL UPDATE Subject: Revised Liftgate Lock Cylinder Replacement Models: 2004-2006 Buick Rainier Models 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Note: When replacing the liftgate lock cylinder, removal of the rear window wiper motor, if equipped, is required. Lock Cylinder Replacement - Liftgate Removal Procedure 1. Remove the rear wiper motor. 2. Remove the lock rod from the lock cylinder. 3. Remove the C clip from the groove in the lock cylinder. Page 415 Page 3940 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 10049 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 3517 Body Control Module: Connector Views Body Control Module (BCM) C1 Part 1 Page 9617 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 1899 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Page 5328 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Page 7362 Fuse Block - Underhood C6 Page 7218 Service and Repair Coolant Drain Plug: Service and Repair Drain Cock Replacement Removal Procedure 1. Drain cooling system. 2. Use a 1/4 inch drive in order to open and remove the drain cock. 3. Remove the drain cock. Installation Procedure 1. Install the drain cock. Notice: Refer to Fastener Notice in Service Precautions. 2. Using a 1/4 inch drive tighten the drain cock. ^ Tighten the drain cock to 2.0 Nm (18 inch lbs.). 3. Refill cooling system. Page 9419 Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: Customer Interest Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: Customer Interest A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Heated Oxygen Sensor (HO2S) 2 Heated Oxygen Sensor (HO2S) 2 Page 9345 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 6639 Page 9683 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 3566 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13316 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Page 5632 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Page 6679 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 1245 Blower Motor Switch: Service and Repair HVAC System - Automatic FRONT AUXILIARY BLOWER MOTOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Press downward and to the right on the front auxiliary blower motor switch. 2. Remove the front auxiliary blower motor switch from the console. 3. Disconnect the electrical connector from the front auxiliary blower motor switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the front auxiliary blower motor switch. 2. Install the front auxiliary blower motor switch to console. 3. Press the front auxiliary blower motor switch into the console. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 6889 Abbreviations And Meanings Part 4 A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Fluid Pump: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Page 8206 Instrument Panel Carrier, Left And Right Page 11085 Front Door Striker: Service and Repair Striker Replacement - Door Removal Procedure 1. Open the door. 2. Mark the position of the striker on the door frame. 3. Remove the 2 bolts that retain the striker to the door frame. 4. Remove the striker and spacer from the door frame. Installation Procedure 1. Install the striker and spacer to the door frame. Important: Do not tighten the bolts at this time. 2. Install the bolts that retain the striker to the door frame. 3. Position the striker and spacer to the door frame as previously marked. Notice: Refer to Fastener Notice in Service Precautions. 4. Fully tighten the bolts that retain the striker to the door frame. Tighten the bolts to 25 N.m (18 lb ft). 5. Close the door. Page 9632 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Diagrams Volume/AM/FM Switch (With RPO Code STW) Page 11084 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. For 2007 vehicles repaired under warranty, use the table. Disclaimer Page 12826 Abbreviations And Meanings Part 3 Page 1800 Windshield Washer Switch: Service and Repair WIPER/WASHER SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the instrument panel (IP) acessory trim plate. 2. Disconnect the electrical connector from the wiper washer switch. 3. Release the wiper washer switch locking tabs. 4. Remove the switch from the trim plate. INSTALLATION PROCEDURE 1. Position the switch to the trim plate. 2. Connect the electrical connector to the wiper washer switch. 3. Install the switch to the instrument panel trim plate, ensuring that the locking tabs are properly seated. 4. Install the instrument panel (IP) acessory trim plate. Page 10896 Registered And Non-Registered Trademarks Part 6 Page 5273 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Page 13478 For vehicles repaired under warranty, use the table. Disclaimer Page 9028 Seat Belt: Service and Repair Seat Belt Replacement - Rear (TrailBlazer EXT, Envoy XL) REMOVAL PROCEDURE 1. Remove the rear seat belt upper guide shoulder bolt. 2. Remove the left rear quarter trim panel. 3. Remove the lower seat belt anchor bolt cover. 4. Remove the rear seat belt floor anchor bolt. 5. Remove the bolt that retains the rear seat belt retractor assembly to the body. 6. Remove the rear seat belt retractor assembly from the vehicle. INSTALLATION PROCEDURE 1. Position the rear seat belt retractor assembly to the vehicle. 2. Install the bolts which retain the rear seat belt retractor assembly to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat belt retractor bolts to 70 N.m (52 lb ft). 3. Install the left rear quarter trim panel. 4. Install the rear seat belt floor anchor bolt. Ensure that the seat belt webbing is not twisted. Tighten Tighten the rear seat belt floor anchor bolt to 70 N.m (52 lb ft). 5. Install the lower seat belt anchor bolt cover. Page 5219 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Page 10334 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 9248 Disclaimer Lower Ball Joint Ball Joint: Service and Repair Lower Ball Joint Lower Ball Joint Replacement Tools Required ^ J9519-E Ball Joint Remover and Installer Set ^ J34874 Booster Seal Remover/installer ^ J41435 Ball Joint Installer ^ J45105-1 Ball Joint Flaring Adapter ^ J45105-2 Receiver Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the steering knuckle with wheel hub and bearing attached. 4. Remove the lower ball joint flange with a chisel. 5. Install J9519-E and J34874 to the lower ball joint. 6. Remove the lower ball joint from the lower control arm using J9519-E and J34874. Installation Procedure Page 13070 Miniwedge (Door Jamb Switch) - LR Page 10643 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 1525 40.6. Install the ring terminal (orange wire) to the underhood fuse block stud (1). 40.7. Locate circuit no. 241 or 441 (ignition 3 brown wire) (PIN B11 or C11) in the existing underhood fuse block harness (1) of C2 (2) and splice bare wire to it using a splice clip. Wrap with electrical tape. 40.8. Locate connector C105 (3), located on the left side inner fender. Separate the connector halves. On the female side of the connector, remove the terminal from cavity F (gray/black wire) and tape back. 40.9. Install the terminal end on the pump wiring harness into cavity F of connector C105. 41. Install the evaporator tube and nut to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 42. Install the coolant recovery reservoir with the accumulator attached. 43. Install the nut and bolt securing the coolant recovery reservoir. 44. Install the coolant hoses to the coolant recovery reservoir. 45. Install the nut retaining the accumulator to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 46. Install the compressor suction hose assembly to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). Page 4854 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 3464 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 12936 Abbreviations And Meanings Part 25 Page 14028 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Page 589 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 13247 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 1735 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Locations Power Seat Page 9075 Tighten Tighten the bolt to 70 N.m (52 lb ft). Page 5669 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 5943 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Locations Front Passenger Seat Keyless Entry - System Inoperative Door Module: Customer Interest Keyless Entry - System Inoperative Bulletin No.: 03-08-52-002 Date: March 27, 2003 TECHNICAL Subject: Remote Keyless Entry Inoperative (Reprogram Liftgate Module) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the Remote Keyless Entry (RKE) is inoperative at times. Cause An anomaly has been identified with the software in the Liftgate Module (RKE functions). The Liftgate Module software is affected when the temperature is approximately 40°C (104°F). Correction Using normal SPS reprogramming procedures, reprogram the LGM Liftgate module. The information was released on TIS version 2.75 or newer broadcast in March 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: All Technical Service Bulletins Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 6258 6. Remove the bleeder valve and bleeder valve cap from the caliper body. 7. Remove the guide pins and guide pin sleeves from the anchor bracket. 8. Clean the following components with denatured alcohol. ^ The bleeder valve ^ The caliper bore ^ The caliper passages ^ The piston ^ The lining contact area on the anchor bracket. 9. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 10. Replace the piston or the caliper if any of the following conditions exist: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Corrosion in the caliper bore. Use crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore Notice: Refer to Fastener Notice in Service Precautions. 11. Replace the bleeder valve cap. ^ Tighten the bleeder valve to 12 Nm (110 inch lbs.). Assembly Procedure 1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake fluid. Page 221 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 10341 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 3704 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Page 4490 Evaporative Emission (EVAP) Canister Purge Solenoid Page 815 Page 11124 10. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge. Installation Procedure 1. Position the service hinge (1) within the scribe marks (2) on the door (3). 2. Mark each hole location on the door according to the service hinge (4). 3. Drill a 3 mm (1/8 in) pilot hole at each location (1). 4. Drill a 13 mm (1/2 in) hole at each pilot hole location (2). 5. Clean and prepare all bare-metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-2001 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an anti-corrosion primer. Page 5888 10. Assemble the bearing retainer in the retainer groove. 11. Continue pressing until you can snap both retainers into place. 12. If seating the retainer is difficult, spring the yoke slightly with a firm blow from a dead blow hammer. 13. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so the snap ring seats in the bearing cup groove. Page 1715 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 7298 Auxiliary Power Outlet: Connector Views Auxiliary Power Outlet - Console Page 40 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 10737 Install a new license plate pocket perimeter gasket onto the backside edge of the pocket housing as shown above, starting at the middle of the seal at the top center of the pocket. This will ensure that the seal will be even. When properly installed, there will be 25-50 mm (1-2 in) on either side of the liftgate release handle (2) that the seal (1) does not reach. DO NOT attempt to install the seal on the liftgate directly below the release handle. Install the license plate pocket assembly onto the liftgate. Refer to the License Plate Pocket Replacement procedure in the Body Rear End (2006 MY and prior) or Exterior Trim sub-section of SI. Modify the tightening sequence for the screws that retain the pocket assembly to the liftgate as follows: Push the entire rear license plate pocket assembly upward in the opening of the liftgate. Inspect the perimeter gasket to see if it is properly retained. Tighten Tighten the rear license plate pocket assembly retaining nuts to 5 N.m (44 lb in) in the following order. Tighten the upper left retaining nut first. Tighten the upper right retaining nut second. Tighten the three lower retaining nuts in any order. Parts Information Page 9914 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 9744 DVD Player Page 10294 Use a scrubbing action, non-abrasive cleaning cassette (part of J 39916-A ) for proper tape player cleaning. This cleaner is a wet-type cleaning system. The wet-type cleaning system uses a cleaning cassette with pads. The pads scrub the tape head as the hubs of the cleaner cassette turn. If you use this type of cleaner, the following conditions may occur: - The radio displays an error. - The cartridge ejects. These conditions are normal and is the result of an added feature in the tape player that detects broken tapes. If an error occurs, insert the cleaning cassette at least 3 times in order to thoroughly clean the tape player. You can also use a non-scrubbing action, wet-type cleaner. This type of cleaner uses a cassette with a fabric belt which cleans the tape head. This type of cleaning cassette will not cause an error, but may not clean the tape player as thoroughly as the scrubbing type cleaner. Page 3943 Registered And Non-Registered Trademarks Part 4 Page 6960 Fuse Block - Rear C3 Part 2 Page 6659 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 6017 6. Remove the 1-2 and 2-3 Shift solenoid retainers. 7. Remove the 1-2 and 2-3 Shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 9440 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 12817 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Locations Side Air Bag: Locations Inflatable Restraint Side Impact Module-Right Service and Repair Map Light Bulb: Service and Repair DOME AND READING LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Carefully grasp the sides of the lens to partially expose the rear retaining tab. 2. Use a flat bladed tool in order to release the rear lens retaining tab. 3. Lower the rear edge of the lens away from the headliner. 4. Move the lens rearward in order to release the front horizontal retaining tab. 5. Remove the lens from the headliner. 6. If replacing the reading lamp bulb (1), remove the reflector (2) from the dome lamp. 7. Remove the reading lamp bulb from the socket. Service and Repair Memory Positioning Module: Service and Repair MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the 3 seat switch bezel screws. 2. Remove 4 nuts that attach the seat pan to the seat assembly. 3. Remove the clip from the front outboard seat pan stud. Discard the clip. 4. Lift the seat pan up in order to allow access to the seat control module retaining screw. 5. Remove the seat control module retaining screw. 6. Disconnect the electrical connectors from the seat control module as necessary. 7. Remove the seat control module from the seat assembly. INSTALLATION PROCEDURE 1. Align and install the locating tabs on the seat control module with the seat pan. 2. Connect the electrical connectors to the seat control module as necessary. Page 250 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 10474 Disclaimer Page 4891 Knock Sensor (KS) 2 Front Page 1907 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 8612 5. Install the foam insulators to the evaporator core-auxiliary lines (3). 6. Install the foam insulators to the thermal expansion valve-auxiliary (4). 7. Install the evaporator core-auxiliary. Page 8284 Air Temperature Sensor Assembly-Inside Page 1506 33. Install the new hose, # 1003 (L6 engine) or # 1004 (V8 engine) onto the auxiliary heater pump inlet port. Connect the other quick connect end to the engine. Page 12199 Mirror Connector, Front Passenger Door Module (FPDM) - C3 Part 1 Page 11402 Trunk / Liftgate Latch: Service and Repair Latch Replacement - Lift Gate Window Latch Replacement - Lift Gate Window Removal Procedure 1. Remove the liftgate window garnish molding. 2. Remove the liftgate trim panel. 3. Remove the bolts that retain the latch to the liftgate. 4. Disconnect the electrical connector. 5. Remove the latch from the liftgate. Installation Procedure 1. Position the latch to the liftgate. 2. Connect the electrical connector. 3. Install the bolts that retain the latch to the lift gate. Notice: Refer to Fastener Notice in Service Precautions. 4. Adjust the portion of the latch to allow the lift gate window striker enter the center of the latch. Tighten the latch bolts to 10 N.m (89 lb in). 5. Install the liftgate trim panel. 6. Install the liftgate window garnish molding. Page 3584 Powertrain Control Module (PCM) C2 Part 5 Page 7288 Abbreviations And Meanings Part 24 Page 4867 For vehicles repaired under warranty, use the table. Disclaimer Engine Controls - Hesitation/Stall/Harsh A/T Upshifts PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 8318 16. Remove the nut and bolt securing the coolant recovery reservoir. 17. Remove the coolant recovery reservoir with the accumulator attached. 18. Remove the evaporator tube nut at the evaporator. 19. Remove the evaporator tube from the evaporator 20. Using the J 43181, disconnect the heater hoses from the core. 20.1. Install the J 43181 to the heater core hose. 20.2. Close the tool around the heater core hose. 20.3. Firmly pull the tool into the quick connect end of the heater hose. 20.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 21. Disconnect the coolant bypass valve hose from the auxiliary rear heater line. 22. Disconnect the coolant bypass valve hose from the engine. 23. Disconnect the electrical connector from the coolant bypass valve. This connector will no longer be used. Tape off with electrical tape. 24. Disconnect the vacuum hose from the coolant bypass valve. 25. Remove the nut retaining the coolant bypass valve to the cowl and remove the coolant bypass valve with hoses attached. 26. Remove the heater hose quick connect retainers from the heater core pipes. 27. Remove the four nuts and the HVAC plate from the dash panel. 28. Attach the new auxiliary heater pump to the new bracket using the supplied retainers as shown. Note the position of the pump on the bracket. Page 12085 Paint Identification Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: * A cathodic immersion primer * A primer/surfacer * A basecoat * A clear top coat (clearcoat) Refer to Label - Service Parts ID in General Information in order to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Page 6864 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 13265 Abbreviations And Meanings Part 3 Page 8985 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Page 3903 Various symbols in order to describe different service operations. Page 5663 6. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (1, 2) securing the transmission mount to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 3. Install the transmission support to the vehicle. Page 9337 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 4387 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE 1. Install the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: Customer Interest OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Diagrams Driver Door Lock Cylinder Switch - LF Page 7319 Fuse: Application and ID Underhood Fuse Block Location View Application Table Part 1 Page 12517 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 1160 Quarterglass Switch - L Page 3930 Abbreviations And Meanings Part 17 Page 7240 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 9329 Page 3283 1. Apply coolant to the end of the heater inlet hoses. 2. Install the heater inlet hose to the inlet hose fitting at the engine block. IMPORTANT:When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 3. Install the coolant bypass valve (6). 4. Install the nut retaining the coolant bypass valve to the cowl. NOTE: Refer to Fastener Notice in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Vehicle Damage Warnings Tighten Tighten the nut to .....10 N.m (89 lb in). 5. Install the vacuum hose to the coolant bypass valve. 6. Install the inlet heater hose to the engine block. 7. Position the inlet heater hose clamp at the engine block using J 38185. 8. Connect the heater inlet hose to the heater core. 9. Install the coolant recovery reservoir. IMPORTANT:Firmly push the quick connect onto the heater core pipe until you hear an audible click. 10. Fill the engine cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. Page 5537 2. Reprogram the PCM with TIS version 4, released in April 2004 or later titled "New calibration to reduce the potential for setting P0706. Also addresses 3-2 downshift feel." With the new calibration, if the P0706 diagnostic fails, the software assumes Park if the engine is not running. If the engine is running, software uses PSM (pressure switch manifold) as back-up. Use one of the tour following procedures to reprogram the PCM: ^ Service Programming System (SPS) Remote Procedure. ^ Service Programming System (SPS) Pass-Thru Procedure. ^ Service Programming System (SPS) Off Board Remote Procedure. ^ Service Programming System (SPS) Off Board Pass-Thru Procedure. Warranty Information For vehicles repaired under warranty, use the table. For additional Labor Operation Information, refer to Warranty Administration Bulletin 02-06-04-057. Disclaimer Page 9976 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 6757 Page 5566 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Page 6691 Abbreviations And Meanings Part 13 Page 1147 Memory Seat Switch, Driver Door Module (DDM) - C4 Page 4164 Steps 22-24 Page 9164 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 4619 Step 6 Locations Passenger Seat Lumbar Actuators, Driver Seat Similar Page 3289 For vehicles repaired under warranty, use the table. Disclaimer Page 4363 Engine Control Module: Diagrams Powertrain Control Module (PCM) C3 Powertrain Control Module (PCM) C3 Part 1 Page 2932 Abbreviations And Meanings Part 4 Page 7505 C800 Part 2 Electrical - Intermittent Interior Electrical Concerns Turn Signal Flasher: All Technical Service Bulletins Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 12043 WA9792/39 - WA990A/19U Page 8161 For vehicles repaired under warranty, use the table. Disclaimer Page 12390 Seat Lumbar Motors And Position Sensors Assembly - Driver Part 2 Page 9083 Seat Belt Retractor: Service and Repair No. 1 Center Rear (TrailBlazer EXT, Envoy XL) REMOVAL PROCEDURE 1. Remove the 3 screws securing the inboard rear seat back cushion latch cover. 2. Remove the rear seat belt anchor nut (2) securing the seat belt (1) to the seat frame. 3. Pull the seat back cover and pad up to expose the seat belt bracket bolts. Refer to Seat Back Cover and Pad Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada)Seat Back Cover and Pad Replacement - Rear No. 1 (TrailBlazer EXT, Envoy XL). 4. Remove the 2 bolts (2) securing the seat belt bracket (1) to the seat back frame. Page 4270 Abbreviations And Meanings Part 4 Page 6951 Fuse Block - Rear C1 Part 4 Page 10317 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 10412 Engine Controls - Underhood Ticking Noise PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Underhood Ticking Noise Bulletin No.: 05-06-02-004 Date: April 06, 2005 TECHNICAL Subject: Underhood Tick Noise at Idle (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada Condition Some customers may comment on an underhood tick noise heard while the vehicle is idling. Technicians may find that the noise does not increase or decrease with changes in the engine idle RPM. The tick noise occurs at approximately one second intervals. Cause This condition may be caused by the electro-viscous fan clutch control function of the Powertrain Control Module (PCM) attempting to keep the fan speed between 300-600 revolutions per minute (RPM). At idle, the cooling fan speed will drag to approximately 500 RPM then oscillate between 300 and 600 RPM. When the fan speed drops below 500 RPM, the PCM will pulse the fan control solenoid. The pulsing of the solenoid is the cause of the ticking noise. Correction Technicians are to verify that the cooling fan clutch is the source of the noise by using either one of the following two methods: ^ Use a Tech 2(R) to command the cooling fan off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. ^ The cooling fan clutch electrical connector, located on the cooling fan shroud, may be disconnected with the engine off. If the ticking noise goes away, the pulsing of the cooling fan clutch is the source of the noise. Be sure to clear any Diagnostic Trouble Codes (DTCs) that may have set while the cooling fan clutch is disconnected. Technicians are to reprogram the PCM with an updated software calibration. The new software calibration is currently available in TIS for all the vehicles listed above. Warranty Information Garnish Molding Replacement Trim Panel: Service and Repair Garnish Molding Replacement Garnish Molding Replacement - Body Side Window - Front GARNISH MOLDING REPLACEMENT - BODY SIDE WINDOW - FRONT (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE 1. Remove the bolt that retains the seat belt upper anchor to the body. 2. Remove the garnish molding from the vehicle. INSTALLATION PROCEDURE 1. Install the garnish molding to the vehicle. 2. Install the seat belt retractor to the body. 3. Install the bolt that retains the seat belt anchor to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the anchor bolt to 70 N.m (52 lb ft). Garnish Molding Replacement - Body Side Window - Rear GARNISH MOLDING REPLACEMENT - BODY SIDE WINDOW - REAR (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE Page 7225 Page 6163 Page 10377 Registered And Non-Registered Trademarks Part 4 Page 7229 Page 3442 Page 6100 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 3418 Heat Shield: Service and Repair Exhaust Muffler Heat Shield Exhaust Muffler Heat Shield Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the catalytic converter heat shield rear 2 bolts where the catalytic converter heat shield connects to the muffler heat shield. 3. Remove the remaining exhaust muffler heat shield bolts and remove the heat shield from the floor panel studs. Installation Procedure 1. Install the muffler heat shield to the floor panel studs placing the muffler heat shield under the rear part of the converter heat shield. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Secure the muffler heat shield with 5 bolts. Tighten the exhaust muffler heat shield bolts to 77 Nm (62 inch lbs.). 3. Lower the vehicle. Page 10420 Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 8256 REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the lower air duct fastener (4). 3. Remove the mid-upper air distribution fastener (6). 4. Remove the mid-upper air distribution duct (6). 5. Remove the lower air duct (5) from the vehicle. INSTALLATION PROCEDURE 1. Install the mid-upper air distribution duct (6). 2. Install the mid-upper air distribution fastener (7). 3. Tighten the mid-upper air distribution screw. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screw to .....1.9 N.m (17 lb in). 4. Install the lower air duct (5) to the vehicle. Tighten Tighten the screw to .....1.9 N.m (17 lb in). 5. Install the lower air duct screw (4). Page 413 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 2669 Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Inspection Procedure Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner. 1. Remove the drive belts. 2. Position a hex-head socket on the belt tensioner pulley bolt head. 3. Move the drive belt tensioner through its full travel. - The movement should feel smooth. - There should be no binding. - The tensioner should return freely. 4. If any binding is observed, replace the tensioner. 5. Install the drive belt. Page 1367 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 6788 Conversion - English/Metric Part 2 A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 4523 Fuel Pressure: Testing and Inspection Fuel System Diagnosis SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Page 1522 34. Install the coolant bypass valve to its original location and secure with a nut. 35. Connect the other end of the new hose from step 29 to the outlet port of the auxiliary heater pump. 36. Connect the vacuum hose to the coolant bypass valve. 37. Connect the coolant bypass valve hose to the auxiliary rear heater line. 38. Install the heater hose quick connect retainers to the heater core pipes. 39. Connect the remaining two hoses to the heater core. 40. Install the new auxiliary heater pump wiring harness to the vehicle. Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 2950 Abbreviations And Meanings Part 22 Page 9001 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 6. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. 5. Access the I/P module connector through the glove box. Page 2738 Installation Procedure 1. Install the engine oil level sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine oil level sensor mounting bolt. ^ Tighten the engine oil level sensor mounting bolt to 10 Nm (89 inch lbs.). 3. Connect the electrical connector to the engine oil level sensor. 4. Install the engine protection shield. 5. Install the engine protection shield mounting bolts. ^ Tighten the engine protection shield mounting bolts to 25 Nm (18 ft. lbs.). Page 5718 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 12997 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 6175 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 10012 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Page 12974 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 868 Abbreviations And Meanings Part 13 Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Diagrams Oil Level Sensor For ECM: Diagrams Engine Oil Level and Temperature Sensor Page 6913 Registered And Non-Registered Trademarks Part 2 Page 4316 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). 7. Disconnect the 40-way body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. Page 12160 Abbreviations And Meanings Part 5 Page 3967 5. Press down and hold the locking tab (1). 6. Disengage the sliding latch retaining the BCM to the rear electrical center. Slide the latch inboard until fully extended, approximately 40 mm (1.6 in). 7. Disconnect the body wiring extension (1) from the BCM. 8. Disconnect the 32-way tan electrical connector (2) from the BCM. 9. Disconnect the 24-way gray electrical connector (1) from the BCM. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 10320 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 692 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement (TrailBlazer, Envoy, Bravada)Headliner Replacement (TrailBlazer EXT, Envoy XL) in Interior Trim. 2. Disconnect the inline connector from the sunroof electrical harness. 3. With an assistant, remove the sunroof module assembly from the vehicle and place on a clean, prepared surface. 4. Remove the sunroof motor/actuator. 5. Remove the screw that retains the sunroof control module to the mounting bracket. 6. Disconnect the 2 electrical connectors from the sunroof control module. 7. Remove the sunroof control module from the mounting bracket. INSTALLATION PROCEDURE 1. Position the sunroof control module to the mounting bracket. IMPORTANT: Ensure that the drive gear is fully indexed and seated to the drive cables. 2. Install the screw that retains the sunroof control module to the mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the sunroof control module screw to 3 N.m (27 lb in). 3. Connect the 2 electrical connectors to the sunroof control module. 4. Install the sunroof motor/actuator to the sunroof module assembly. 5. With an assistant, install the sunroof module assembly to the vehicle. 6. Connect the inline connector on the sunroof electrical harness. 7. Install the headliner. Description and Operation Evaporative System Service Port: Description and Operation EVAP SERVICE PORT The EVAP service port is located in the EVAP purge pipe between the EVAP purge solenoid and the EVAP canister. The service port is identified by a green colored cap. Page 10375 Registered And Non-Registered Trademarks Part 2 Page 8282 Air Temperature Sensor-Upper Lift Page 9381 Abbreviations And Meanings Part 15 Page 12458 9. Install the latch bezels. 10. Install the seat cushion bracket. 11. Install the seat cushion in the vehicle. Seat Cushion Cover and Pad Replacement - Rear No. 1 - 2 SEAT CUSHION COVER AND PAD REPLACEMENT - REAR NO. 1 (TRAILBLAZER EXT, ENVOY XL) TOOLS REQUIRED J 36796Clip Removal Tool REMOVAL PROCEDURE 1. Release the J-strips that retain the cover to the seat pan. 2. Compress the foam and partially remove the seat cover assembly from the seat pan. 3. Remove the cover from the cushion by separating the retaining strips. IMPORTANT: When separating the seat cover retaining strips, do not pull the adhesive-backed strip from the seat pad. 4. Separate and remove the cushion and cover assembly from the seat pan. 5. Release the reinforcement bar from the hog-rings. 6. Remove the cover from the cushion. INSTALLATION PROCEDURE 1. Install the cover to the cushion. 2. Install the reinforcement bar to the hog-rings. 3. Attach the retaining strips that retain the cover to the cushion. 4. In order to install the seat cushion to the seat pan, perform the following: 5. Install the seat pan to the cushion and cover assembly. 6. Compress the foam and install the seat cover and cushion to the seat pan. Page 12173 Abbreviations And Meanings Part 18 Page 9358 Conversion - English/Metric Part 2 Page 3439 Page 52 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 12187 Registered And Non-Registered Trademarks Part 6 Page 267 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 9973 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 11705 Trim Panel: Service and Repair Garnish Molding Replacement - Body Side Window - Front (TrailBlazer EXT, Envoy XL) Garnish Molding Replacement - Body Side Window - Front (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the bolt that retains the seat belt upper anchor to the body. 2. Remove the garnish molding from the vehicle. Installation Procedure 1. Install the garnish molding to the vehicle. 2. Install the seat belt retractor to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the seat belt anchor to the body. Tighten the anchor bolt to 70 N.m (52 lb ft). Page 6756 Page 5311 If water or coolant is found in the transmission, the following components MUST be replaced. ^ Replace all of the rubber type seals. ^ Replace all of the composition4aced clutch plate assemblies including the band. ^ Replace all of the nylon parts (Thrust Washers). ^ Replace the torque converter. ^ Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. ^ Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052C or newer - Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator WITH the transmission REMOVED from vehicle. 1. Remove the transmission fluid filler tube from the transmission. 2. Replace the transmission fill tube seal, P/N 1259475. 3. Replace the transmission fill tube, P/N 15000220, following the appropriate SI Document for Transmission Installation. 4. Replace the transmission fluid level indicator, P/N 15069769 when appropriate during the transmission installation. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator with the transmission in the vehicle. 1. Remove the air cleaner outlet duct. 2. Remove the transmission fluid level indicator from the filler tube. 3. Remove the filler tube nut (2) located on the right side of the engine. 4. Remove the filler tube from the vehicle. Page 8039 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Page 3478 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ....................................... 334 - 375 kPa (48 - 54 PSI) Fuel Pressure Drop (After 1 minute) ............................................................................................................................................................. 34 kPa (5 PSI) Page 8964 Side Air Bag: Service and Repair INFLATABLE RESTRAINT SIDE IMPACT MODULE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 2 and SIR Disabling and Enabling Zone 6. CAUTION: Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. - Refer to SIR Caution in Service Precautions. - Following the deployment of a side impact air bag, inspect the following parts for damage. Replace these parts if necessary: The seat cushion frame - The seat recliner, if equipped - The seat adjuster - The seat back frame Failure to do so may cause future personal injury. 1. Remove the seat assembly from the vehicle. 2. Remove the seat trim panel. 3. Remove the seat back cover and pad. 4. Remove the front seat back panel. 5. Remove the push pin (2) securing the top of the seat belt retractor assembly to the seat back frame. 6. Remove the 2 screws (1) that secure the inflatable side impact module to the seat back frame. 7. Disconnect the SIR wiring harness from the module. 8. Remove the side impact module. 9. Fully deploy the module before disposal. If the module was replaced under warranty, fully deploy and dispose of the module after the required retention period. INSTALLATION PROCEDURE 1. Connect the SIR wiring harness to the module. Page 11141 Page 1738 Abbreviations And Meanings Part 2 Page 9494 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 2063 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Page 3235 fan noise can be expected with the updated PCM software calibrations. The last area of customer concern is the operation of the HVAC system blower motor. For vehicles equipped with automatic control HVAC systems (RPO CJ2), the blower motor fan speed will be limited to 80% of maximum when the HVAC system is operating in the automatic mode. To obtain maximum blower motor speed, instruct the customer to manually adjust the blower motor speed to the highest setting. Parts Information Warranty Information (excluding Saab U.S. Models) Disclaimer Page 6183 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 3251 fan noise can be expected with the updated PCM software calibrations. The last area of customer concern is the operation of the HVAC system blower motor. For vehicles equipped with automatic control HVAC systems (RPO CJ2), the blower motor fan speed will be limited to 80% of maximum when the HVAC system is operating in the automatic mode. To obtain maximum blower motor speed, instruct the customer to manually adjust the blower motor speed to the highest setting. Parts Information Warranty Information (excluding Saab U.S. Models) Disclaimer Page 10055 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 5607 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Page 4505 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement Engine/Chassis REMOVAL PROCEDURE 1. Remove the EVAP/fuel hose/pipe assembly. 2. Remove the EVAP purge pipe (3) from the EVAP/fuel hose/pipe assembly. INSTALLATION PROCEDURE 1. Place the new EVAP purge pipe (3) in the EVAP/fuel hose/pipe assembly. 2. Install the EVAP/fuel hose/pipe assembly. Page 6994 Application Table Part 3 Location View Page 8222 Console Mode Actuator (Body Type VIN 6) Page 10332 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 10413 Page 1777 3. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 4. Inspect the radio or the OnStar(R) system, if equipped, to verify reception. 5. Close the liftgate window. Page 8321 33. Install the new hose, # 1003 (L6 engine) or # 1004 (V8 engine) onto the auxiliary heater pump inlet port. Connect the other quick connect end to the engine. Page 231 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Read this procedure carefully and completely. 2. The BCM will not function properly if the Setup New BCM procedure is not performed. 3. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. A/C - Musty Odors On Start Up Control Module HVAC: Customer Interest A/C - Musty Odors On Start Up Bulletin No.: 05-01-39-002A Date: March 17, 2006 TECHNICAL Subject: Musty Odor from HVAC System (Reprogram HVAC Control Module to Enable Afterblow Function) Models: 2004-2006 Buick Rainier 2003-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2003-2004 Oldsmobile Bravada with Automatic Temperature Control HVAC System (RPO CJ2) Supercede: This bulletin is being revised to add the 2006 model year and update the calibration release date. Please discard Corporate Bulletin Number 05-01-39-002 (Section 01 - HVAC). Condition Some customers may comment on a musty odor from the Heating, Ventilation and Air Conditioning (HVAC) system. This condition occurs most often on initial start up after the vehicle was driven on a hot humid day. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. Correction Important: The afterblow function should not be enabled until after the purpose and operation of it is explained to your customer and they approve of the change. Once the afterblow function is enabled there are no calibrations currently released to disable it. Technicians are to reprogram the HVAC Control Module with an updated software calibration that will enable the afterblow function. The new calibration will be released beginning with TIS satellite data update version 2.0, which was made available February 5, 2006. The blower motor will turn on approximately 10 minutes after the vehicle is shut off. The blower motor will run continuously for 10 minutes at a 30% duty cycle. The afterblow function will only activate if the air conditioning compressor was engaged during conditions of high ambient temperature. If the vehicle is started within 10 minutes of the last key off, the afterblow function from the previous key cycle will be cancelled. Technicians should not attempt to reprogram a vehicle with a Manual Temperature Control HVAC system (RPO CJ3). Technicians should perform this HVAC Control Module reprogram instead of installing the Electronic Evaporator Dryer Module Kit referred to in the Air Conditioning Odor bulletin, Corporate Bulletin Number 99-01-39-004A. Warranty Information Page 7602 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Page 716 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four new T-25 TORCH screws (1) in the EBCM (2). ^ Tighten the four T-25 TORX screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM (2). 4. Revise the tire calibration using the Scan Tool Tire Size Calibration function. Page 9439 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 11392 Trunk / Liftgate Handle: Service and Repair Handle/Striker Replacement - Lift Gate Window Removal Procedure 1. Open the lift gate window. 2. Remove the nuts retaining the striker assembly to the lift gate window. 3. Remove the handle and striker assembly from the lift gate window. Installation Procedure 1. Install the handle and striker assembly to the lift gate window. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the nuts retaining the striker assembly to the lift gate window. Tighten the nuts to 6 N.m (53 lb in). 3. Check the lift gate window for proper operation, adjust if necessary. Refer to Striker Adjustment Lift Gate Window. Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement Tools Required - J 44218 Seal Installer Removal Procedure Important: Do not damage the engine front cover or the crankshaft. 1. Remove the crankshaft balancer. 2. Pry out the crankshaft front oil seal using a suitable tool. Use the provided slots for prying out the seal. Installation Procedure 1. Apply the engine oil to the outside diameter of the crankshaft front oil seal. Page 5905 Shift Effort Shift effort will vary among different style transmissions and synchronizer designs. Usually the more heavy duty the transmission, the higher the shift effort because of the increased mass of the components. Shift effort can also be higher in cold weather because the fluid will be thicker. Medium duty transmissions will not shift as quickly as a Corvette transmission. To reduce shift effort, do not attempt to rush the shift - allow the synchronizers to work as designed. Shifting harder will only increase the chance of rushing past the synchronizer leading to grinding while shifting. Non-Synchronized Gears Some light duty truck transmissions in 1st gear (creeper-gear) and reverse gears in various transmissions, along with all gears in some medium duty transmissions, may be non-synchronized. This means there is not a mechanism to match input and output shaft speeds to allow for a smooth shift. This function is left up to the driver. This can be noticed if a shift into 1st or reverse is attempted while the vehicle is rolling or before the input shaft stops rotating leading to a gear grind. The grinding can be reduced by coming to a complete stop and pausing for a moment before shifting into the 1st or reverse gear. Some slight grinding can be expected. In medium duty non-synchronized transmissions, the driver must match input shaft (engine) speed to output shaft (driveshaft) speed with every shift. This can be accomplished by double clutching, or by using other methods. If the driver is not able to perform this function properly, there will be gear grinding with each improperly completed shift. Driver training may be required to correct this condition. Clutch brakes are used in medium duty non-synchronized transmissions to allow a shift into gear at a stop. The clutch brake is used to stop the input shaft from spinning, allowing a shift into gear at a stop without grinding. The clutch brake is activated by pressing the clutch pedal all the way to the floor. When the clutch brake is used, it is possible to have a blocked shift with the vehicle stationary. If this occurs, engage the clutch slightly to rotate the input gear to allow the shift. The clutch brake is intended to only be used while at a stop. Care must be taken to not activate the clutch brake while shifting between gears. This could lead to excessive grinding or a blocked or missed shift. Skip Shift Currently, the Cadillac CTS-V, Pontiac GTO, Chevrolet Corvette and Camaro SS (other models may follow) equipped with the 6-speed manual transmission have a feature referred to as a "skip-shift." This feature only allows a shift from 1st to 4th gear when the indicator lamp is illuminated on the dash. Dealers cannot disable this feature as it was established to help meet fuel economy standards. The conditions for this feature are: engine coolant at normal operating temperature, vehicle speed of 24-31 km/h (15-19 mph), 21% or less throttle being used (refer to Service Information or the Owner Manual for more details.) Disclaimer Page 12538 Abbreviations And Meanings Part 6 Page 11967 Parts Information Repair Claim Information - Refer to the extent of the repair instructions as approved by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) Warranty Information (excluding Saab U.S. Models) Page 3090 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Page 2366 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 3793 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Page 6901 Abbreviations And Meanings Part 16 Page 11902 Switch Replacement - Door Lock and Side Window - Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. 4. If replacing the passenger door module, program the passenger door module. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. IMPORTANT: When replacing the passenger door module, the set up procedure must be performed. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 4695 15. Remove the EVAP/fuel hose/pipe assembly retaining clips. IMPORTANT: Note the position of the EVAP/fuel hose/pipe assembly clips before disassembly. 16. Remove the fuel feed (1), fuel return (2), or EVAP purge (3) pipe to be replaced. INSTALLATION PROCEDURE 1. Place the new fuel feed (1), fuel return (2), or EVAP purge (3) pipe with the remaining pipes in the EVAP/fuel hose/pipe assembly. 2. Install the EVAP/fuel hose/pipe assembly clips as noted during disassembly. 3. Position the EVAP/fuel hose/pipe assembly along the engine and transmission. Page 12485 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Page 1021 40.5. Route the other end of the harness along the rear of the engine compartment to the left side and secure to the cross bar and dash panel with tie straps. Page 12473 3. Remove the seat latch bezels. 4. Use the J 36796 to remove the push pins (1) on the underside of the seat bottom, in order to start the seat cushion removal procedure. 5. Fold the carpet back in order to release the J-strips that retain the cover to the seat pan. 6. Starting at either forward corner, compress the foam and partially remove the seat cover assembly from the seat pan. Important: When separating the seat cover retaining strips, do not pull the adhesive-backed strip from the seat pad. 7. Remove the cover from the cushion by separating the retaining strips. 8. Separate and remove the cushion and cover assembly from the seat pan. 9. Release the reinforcement bar from the hog-rings. 10. Remove the cover from the cushion. Installation Procedure 1. Install the cover to the cushion. 2. Install the reinforcement bar to the hog-rings. 3. Attach the retaining strips that retain the cover to the cushion. 4. In order to install the seat cushion to the seat pan, perform the following: 5. Install the seat pan to the cushion and cover assembly. 6. Compress the foam and install the seat cover and cushion to the seat pan. 7. Connect the J-strips that retain the cover to the seat pan. Page 2206 Application Table Part 4 Location View Page 3099 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Locations Automatic Transmission Page 677 Liftgate Module (LGM) C3 (Except XUV) Page 10662 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 4113 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Engine - Piston Application/Usage Piston: Technical Service Bulletins Engine - Piston Application/Usage Bulletin No.: 03-06-01-028 Date: November 19, 2003 INFORMATION Subject: Information on Correct Piston Usage Models: 2002-2003 Chevrolet Trailblazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Inline 6 Engine (VINS - RPO LL8) Should any of the above vehicles require a piston for any reason, the following replacement part number should be used. 88984235 - Standard size piston with piston pin and rings. Although this replacement piston may not appear to match the piston that is removed, it has been designed to replace all 2002 and 2003 model year engine pistons. This change was implemented into production engines beginning with EUN (engine unit number): V301290522. The EUN may be found on the left side of the engine under the A/C compressor bracket or at the rear on the back of the cam cover. Important: When replacing pistons, all six pistons must be replaced if the EUN is below the above number or if the EUN cannot be located. If pistons of different types were installed in the engine, excessive engine vibration would result. Piston rings for these engines will not be released and will require a piston change if a piston ring change is indicated. Parts Information Parts are expected to be available from GMSPO on December 1, 2003. Disclaimer Page 5979 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8276 1. Install the air outlet duct-rear (3) to the console support bracket (1). 2. Install the push pin (1). 3. Install the console support bracket. Page 11667 2. If the vehicle is equipped with a sunroof, partially raise the headliner and connect the sunroof assembly electrical connector. 3. With the aid of an assistant, fully raise the headliner Coupling Replacement - Antenna Inner and Coupling Replacement - Antenna Outer and install the left inboard sunshade retaining clip (5). 4. Install the right rear push pin (2) 5. Install the left rear push pin (3). 6. Install the assist handles to the roof panel. 7. Connect the electrical connector to the cellular phone antenna. 8. Install the coat hooks to the roof panel. 9. Install the upper rear quarter trim panels. 10. Connect the navigation antenna electrical connector, if equipped. 11. Connect the rain sensor electrical connector, if equipped. 12. Connect the inside rear view mirror electrical connector (6). 13. If the vehicle is NOT equipped with a sunroof, seat the 2 interlocking strips (1). 14. If the vehicle is equipped with a sunroof, seat the 6 interlocking strips. 15. Reach underneath the carpet and remove the headliner harness electrical connector (1) from the IP wire harness. A/C - Poor Rear Heater Performance Auxiliary Water Pump: All Technical Service Bulletins A/C - Poor Rear Heater Performance Bulletin No.: 05-01-37-002A Date: November 01, 2005 TECHNICAL Subject: Poor Rear Heat Performance (Install Auxiliary Heater Pump) Models: 2003-2005 Chevrolet TrailBlazer EXT 2003-2005 GMC Envoy XL Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 05-01-37-002 (Section 01 - HVAC). Important: Implementation of this Service Bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on poor 2nd and/or 3rd row seating heater performance when the vehicle is at idle. Cause This condition may be due to lack of coolant circulation to the rear heater core. Correction Install auxiliary heater pump package, P/N 89024885 (L6 Engine RPO LL8) or P/N 89024886 (V8 Engine RPO LM4 or LH6). This pump will improve coolant flow to the rear heater core. Use the procedure listed below. 1. Recover the A/C refrigerant. 2. Drain the cooling system. 3. Disconnect the negative battery cable. 4. Remove the fender rear upper brace. 5. Remove the air cleaner cover. 6. Remove the air cleaner filter element and air outlet duct. 7. Remove the air inlet duct from the lower air cleaner housing/washer solvent tank assembly. 8. Disconnect the washer solvent tank electrical and remove wiring harness from the retaining clips. 9. Disconnect the washer pump hoses and plug the pump outlet ports to prevent loss of washer solvent. 10. Remove the two air cleaner housing/washer tank assembly retaining nuts from the mounting studs. 11. Lift the lower air cleaner housing/washer tank assembly off of the studs and remove the assembly. 12. On the A/C accumulator, disconnect the electrical connector from the low pressure switch. 13. Remove the compressor suction hose assembly from the accumulator. 14. Remove the nut retaining the accumulator to the evaporator. 15. Remove the coolant hoses from the coolant recovery reservoir. Page 10688 Page 465 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 7273 Abbreviations And Meanings Part 9 Page 12226 Memory Seat Module - Driver C2 Part 2 Page 7734 1. Lubricate the inner tie rod (3) threads with a suitable chassis lubricant before installing the outer tie rod (2). 2. Install the outer tie rods. 3. Install the power steering gear to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the power steering gear mounting bolts. Tighten the power steering gear mounting bolts to 110 Nm (81 ft. lbs.). 5. Remove the support from the power steering gear. 6. Install the power steering hose assembly to the power steering gear. 7. Install the power steering hose assembly to power steering gear retaining bolt. Tighten the power steering hose assembly to power steering gear retaining bolt to 12 Nm (106 inch lbs.). 8. Install the steering gear crossmember. 9. Connect the lower intermediate shaft to the power steering gear. Engine - Broken Bolt Extraction Information Cylinder Head Bolts: Technical Service Bulletins Engine - Broken Bolt Extraction Information INFORMATION Bulletin No.: 05-06-01-026B Date: October 21, 2008 Subject: Information On Torque to Yield Bolt Breakage and Use of Bolt Extractor Tool Kit Part Number EN-47702 for Removing Broken Cylinder Head or Main Bearing Cap Bolts on Inline Truck Engines Models: 2004-2007 Buick Rainier 2002-2009 Chevrolet TrailBlazer 2004-2009 Chevrolet Colorado 2002-2009 GMC Envoy 2004-2009 GMC Canyon 2002-2004 Oldsmobile Bravada 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with 2.8L, 2.9L, 3.5L, 3.7L or 4.2L Vortec Inline Engine (VINs 8, 9, 6, E, S - RPOs LK5, LLV, L52, LLR, LL8) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-06-01-026A (Section 06 - Engine/Propulsion System). A Torque To Yield (TTY) bolt, like a cylinder head bolt or main bearing cap bolt, may break during repair procedures. Interaction between a TTY bolt and threads may cause the bolt to bind or break on removal. Prior to removing the cylinder head or main cap bolts, perform the following procedure: Using an appropriately sized punch and hammer, rap on the head of each bolt. The vibration produced by this procedure will assist in successful removal. If a head bolt or main bolt breaks during engine disassembly, a broken bolt extractor kit (EN-47702) has been released to assist in removal of the remaining bolt segment. Many times the remaining bolt segment will back out easily with a pick tool or a reverse twist drill bit. Bolt Replacement & Tightening Important: Never reuse TTY main bearing or cylinder head bolts. Always make sure that the engine block threaded holes are clean and do not place oil or threadlocker on the bolts. Utilize a thread chase tool followed by cleaning with dry compressed air to insure threads are clean and dry prior to installation of new TTY bolts. Bolts that creak and snap while tightening will fail due to excessive torque caused by threads contaminated with debris, antifreeze or oil. Trace amounts of oil or antifreeze will cause this condition. In extreme cases the threads may need additional cleaning with a non-residue cleaner like a brake clean product followed by drying with clean & dry compressed air. Page 2506 6. Install the top chain guide. 7. Add threadlocker to the top chain guide bolt threads. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number. 8. Install the top chain guide bolts. Tighten the top chain guide bolts to 10 Nm (89 lb in). 9. Install the camshaft cover. Refer to Camshaft Cover Replacement. Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Removal Procedure 1. Open the liftgate. 2. Pull the liftgate weatherstrip from the liftgate opening pinch-weld flange. Installation Procedure 1. Install the liftgate weatherstrip, starting at the top center of the liftgate opening position the liftgate weatherstrip to the pinch-weld flange and working down the right and left sides towards the bottom center, being careful not to stretch the liftgate weatherstrip while installing it. 2. Install the butt joint seam at the center of the bottom pinch-weld flange. 3. Use a rubber mallet to ensure full engagement of the liftgate weatherstrip to the pinch-weld flange. 4. Spooning of the liftgate weatherstrip may be required to complete the installation of the liftgate weatherstrip. 5. Close the liftgate. Page 2516 NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 7. Install the camshaft caps onto their original journal. Tighten the camshaft cap bolts to 12 Nm (106 inch lbs.). 8. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222. 9. Install the intake camshaft sprocket washer, and the bolt, and the exhaust camshaft actuator bolt. - Tighten the intake camshaft sprocket bolt the first pass 20 Nm (15 ft. lbs.). - Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100°. - Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 ft. lbs.). - Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135°. 10. Install the camshaft cover. Page 2774 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 11036 Front Door Hinge: Service and Repair Door Side Hinge Door Side Hinge REMOVAL PROCEDURE IMPORTANT: The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all hinges. 1. Remove all of the related panels and components. 2. Remove the sealer surrounding the hinge (1). 3. Scribe the location of the hinge (1). 4. Hand-sand the existing hinge (1) with 100 grit sandpaper to locate the four weld locations. IMPORTANT: Punch the center of the weld so that as much of the weld as possible is removed during drilling. Page 1707 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 7659 10. Remove the power steering hose assembly bracket retaining bolt at the wheel well. 11. Disconnect the power steering hose assembly bracket from the wheel well. 12. Remove the power steering hose assembly to frame brackets retaining bolts. 13. Remove the power steering hose assembly to front crossmember bracket mounting bolt. 14. Remove the power steering pressure hose (1) and power steering cooler hose (2) from the power steering pump. 15. Remove the power steering hose assembly from the vehicle. Installation Procedure 1. Install the power steering hose assembly to the vehicle. 2. Install the power steering cooler hose (2) the the power steering pump. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering pressure hose (1) to the power steering pump. Locations Engine Page 10369 Abbreviations And Meanings Part 22 Page 3981 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE 1. Install the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Page 12917 Abbreviations And Meanings Part 6 Page 6341 5. Install the brake caliper mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the caliper mounting bracket bolts. ^ Tighten the caliper mounting bracket bolts to 150 Nm (110 ft. lbs.). 7. Install the rear brake pad hardware to the brake caliper mounting bracket. 8. Install the brake pads to the brake caliper mounting bracket. Page 7313 Location View Page 6219 Abbreviations And Meanings Part 18 Page 12442 2. Remove the 4 nuts that retain the seat pan to the seat adjuster assembly. 3. Remove the clip from the front outboard seat pan stud , if equipped. Discard the clip. 4. Release the J strips (1,3) on each side of the seat cushion. 5. Release the front/rear J strips (2,4). 6. Remove the SIR electrical harness (2) from the seat pan. 7. Remove the seat electrical harness from the seat pan. 8. Remove the wire harness fasteners from the seat pan. 9. Disconnect the seat cushion heater electrical connector, if equipped. Page 3441 Page 11212 Rear Door Striker: Adjustments Lock Striker Adjustment - Door Adjustment Procedure 1. Open the door. 2. Remove the lock striker from the door opening. 3. Close the door with the lock striker removed. 4. Verify proper door fit to the door opening and weatherstrips. Adjust the door frame as necessary. 5. Install the lock striker to the door opening. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the lock striker screws retaining the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. 7. Using a large flat-bladed tool, rock the striker up and down to loosen the lock striker backing plate from the body. Important: Do not slam the door. 8. Close the door while holding the outside handle in the open position to align the lock striker. If necessary, adjust the lock striker position to allow the door to close with minimum effort. 9. Open the door. 10. Finish tightening the lock striker screws. Tighten the lock striker screws to 25 N.m (18 lb ft). 11. Close the door. Page 10198 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 2697 valve would indicate a faulty pump. Page 6633 Page 6974 Fuse Block - Underhood C2 Part 4 Page 950 Powertrain Control Module (PCM) C2 Part 5 Page 5670 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 13977 Steps 8-10 Page 263 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 4073 Page 6479 7. Remove the rear brake rotor. 8. Remove the axle shaft. 9. Remove the park brake shoe. 10. Remove the backing plate bolts. 11. Remove the park brake actuator lever housing from the backing plate. 12. Using denatured alcohol, clean the backing plate and parking brake actuator. 13. Using non-lubricated, filtered air, dry the backing plate. Installation Procedure A/T - Cracked Case Diagnosis Case: Technical Service Bulletins A/T - Cracked Case Diagnosis Bulletin No.: 02-07-30-024B Date: August 18, 2005 INFORMATION Subject: Diagnosis of Cracked or Broken Transmission Case Models: 2006 and Prior Cars and Light Duty Trucks 2006 and Prior HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60/4L60-E/4L65-E or 4L80-E/4L85-E or Allison(R) Series 1000 Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-07-30-024A (Section 07 - Transmission/Transaxle). Diagnosing the cause of a cracked or broken transmission case requires additional diagnosis and repair or a repeat failure will occur. A cracked or broken transmission case is most often the result of abnormal external torsional forces acting on the transmission case. If none of the conditions listed below are apparent, an internal transmission component inspection may be required. Repairs of this type may be the result of external damage or abuse for which General Motors is not responsible. They are not the result of defects in materials or workmanship. If in doubt, contact your General Motors Service Representative. The following items should be considered: ^ It is important to inspect the vehicle for signs of an out of line condition, impact damage or foreign material to the following components: - The transmission - The engine mounts - The transmission rear mount and crossmember - Vehicle frame damage that alters the front to rear alignment of the driveshaft - The driveshafts (both front and rear) - The wheels (caked with mud, concrete, etc.) - The tires (roundness, lack of cupping, excessive balance weights) - The transfer case (if the vehicle is 4WD) ^ A worn or damaged driveshaft U-Joint has shown to be a frequent cause of transmission case cracking, especially on vehicles that see extended periods of highway driving. Always inspect the U-joint condition when diagnosing this condition. ^ For driveshaft damage or imbalance, Inspect the driveshafts (both front and rear) for dents, straightness/runout or signs of missing balance weights. Also, inspect for foreign material such as undercoat sprayed on the driveshaft. ^ The driveshaft working angles may be excessive or non-canceling, especially if the vehicle carrying height has been altered (lifted or lowered) or if the frame has been extended or modified. ^ Damaged or worn upper or lower rear control arms or bushings. ^ A rear axle that is not seated in the rear spring properly (leaf spring vehicles). ^ Broken rear springs and or worn leaf spring bushings. Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Ride/Trim Height Inspection Procedure Alignment: Service and Repair Ride/Trim Height Inspection Procedure TRIM HEIGHT MEASUREMENTS Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following prior to measuring trim heights: ^ Make sure the vehicle is on a level surface, such as an alignment rack. ^ Set the tire pressures to specifications. ^ Check the fuel level. Add additional weight if necessary to simulate a full tank. ^ To ensure proper weight distribution make sure the rear storage compartment is empty. ^ Close the doors and hood. Z Height Measurement - Front The Z height measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm to adjust the Z height. Vehicles without torsion bars have no adjustment and may require replacement of suspension components. Important: All dimensions are measured vertical to the ground. 1. Place hands on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (3) down to the lower corner (5) of the lower ball joint (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation and measurement 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the high and the low measurements. Cross vehicle Z heights should be within 24 mm (0.9 inch). 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension. ^ Collision damage. D Height Measurement - Rear The D height measurement determines the proper ride height for the rear end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. Important: All dimensions are measured vertical to the ground. 1. Place hands on the rear bumper and jounce the rear of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. Page 10381 Accessory Delay Module: Electrical Diagrams Retained Accessory Power (RAP) Diagram Page 3913 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Diagrams Power Door Lock Actuator: Diagrams Door Lock Actuator - Driver Page 9523 Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 6860 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 10552 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 13907 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 12963 Page 11710 1. Remove the front and rear door sill plates. 2. Move the seat to a forward position. 3. Release the 4 retaining clips that attach the garnish molding to the center pillar. 4. Disconnect the electrical connector from the temperature sensor, if equipped. 5. Remove the garnish molding from the vehicle. INSTALLATION PROCEDURE 1. Position the garnish molding to the center pillar. 2. Connect the electrical connector to the temperature sensor, if equipped. 3. Index the positioning tabs on the garnish molding to the corresponding holes in the center pillar. 4. Seat the 4 garnish molding retaining tabs to the center pillar. 5. Return the seat to neutral position. 6. Install the front and rear door sill plates. Garnish Molding Replacement - Rear Window GARNISH MOLDING REPLACEMENT - REAR WINDOW REMOVAL PROCEDURE 1. Open the liftgate. Page 9500 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 6558 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four new T-25 TORCH screws (1) in the EBCM (2). ^ Tighten the four T-25 TORX screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM (2). 4. Revise the tire calibration using the Scan Tool Tire Size Calibration function. Page 2247 Fuse Block - Underhood C7 Page 12046 Paint: Application and ID Parts ID Label Location LABEL - SERVICE PARTS ID Labeling - Service Parts ID The service parts identification label is located on the instrument panel storage compartment door in order to help service and parts personnel identify the vehicle's original parts and the vehicle's original options. Page 12565 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 9444 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 2531 Bolt Extractor Tool Kit Part Number EN-47702 The bolt extractor kit EN-47702 provides the following components to assist in removal of the broken bolt segment: 1. One 5/32" reverse twist drill - part number EN-47702-6 2. One double-ended drill pilot insert - part number EN-47702-1 (ensures a straight drilling procedure) 3. Drill pilot inserts for larger diameter heads or main cap bolts - part number EN-47702-2 (ensure a straight drilling procedure) 4. Bolt extraction # 3 EZ out - part number EN-47702-3 (after the drilling procedure) 5. Bottom tap (M11 X 2) - part number EN-47702-5 (for the head bolts to chase the threads after the completion of bolt removal) 6. Bottom tap (M10 X 1.5) - part number EN-47702-4 (for the main bolts to chase the threads after the completion of bolt removal) Disclaimer Page 788 Application Table Part 3 Page 7512 Application Table Part 2 Page 7378 Application Table Part 4 Location View Page 12293 Sunroof / Moonroof Switch: Service and Repair SUNROOF SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the overhead console in order to access the sunroof switch. 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat bladed tool carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. INSTALLATION PROCEDURE 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. Page 3011 14. Remove the timing chain tensioner shoe bolt. 15. Remove the timing chain tensioner shoe. 16. Remove the timing chain tensioner guide bolts. 17. Remove the timing chain tensioner guide. 18. Remove the timing chain tensioner bolts. 19. Remove the timing chain tensioner. Installation Procedure NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Page 4593 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic converter. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Page 13683 service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers, possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in Page 11846 Registered And Non-Registered Trademarks Part 5 Page 12920 Abbreviations And Meanings Part 9 Page 9271 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 2408 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 3625 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. 1. Install the CKP sensor into the engine block. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 21 Page 6461 1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return spring in denatured alcohol, or equivalent. 2. Inspect the master cylinder bore. inlet and outlet ports, the secondary piston (1). and the return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist. 3. Dry the master cylinder and the individual components with non-lubricated. filtered air. 4. Lubricate the master cylinder bore the secondary piston (1), the return spring, and all of the individual overhaul components with Delco Supreme 11, GM U.S. P/N 12377967, GM Canada P/N 992667, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto the secondary piston. 6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore. 7. Install the lubricated, new primary piston assembly (2) into the cylinder bore. 8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston retainer. 9. Install the master cylinder reservoir to the master cylinder. Refer to Master Cylinder Reservoir Replacement. 10. Install the reservoir cap and diaphragm to the reservoir. Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 11468 Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 13930 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 13052 11. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 12. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 13. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 14. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 9 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 11488 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Lighting - Turn Signal Flasher Sticks ON Turn Signal Flasher: All Technical Service Bulletins Lighting - Turn Signal Flasher Sticks ON Bulletin No.: 03-08-42-014 Date: December 09, 2003 INFORMATION Subject: New Turn Signal Flasher Module Availability Models: 2004 Buick Rainier 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet SSR - Built Prior to VIN Breakpoint 3B101657 2003-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2003-2004 Oldsmobile Bravada Built After April 2003 New Flasher Module Availability Important: Always use the part number listed in the table below for flasher replacement on the above vehicles. The factory installed Turn Signal Flasher Module in the vehicles listed above has been superseded by a revised part number. Do not use the original flasher module part number if a replacement is needed. An anomaly has been observed in the original production flasher that could cause the flasher module to stick in the "on" position if the directional signal is used for an extended period of time. Always use the part number listed in the table below for flasher replacement on the above vehicles. Parts Information Parts are currently available from GMSPO. Disclaimer Page 35 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 10192 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 4644 6. Install the fuel return pipe retainer. Tighten Tighten the return pipe retainer screw to 8 N.m (71 lb in). 7. Connect the fuel return pipe. 8. Connect the fuel pressure regulator vacuum line. 9. Connect the negative battery cable. 10. Inspect for leaks. 10.1. Turn ON the ignition for 2 seconds. 10.2. Turn OFF the ignition for 10 seconds. 10.3. Turn ON the ignition. 10.4. Inspect for fuel leaks. 11. Install the engine wiring harness into the retaining clips at the front of the engine. 12. Install the air intake resonator. Service and Repair Axle Bearing: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement Tools Required ^ J8092 Universal Driver Handle- 3/4 inch - 10 ^ J21128 Axle Pinion Oil Seal Installer ^ J23690 Bearing Installer ^ J2619-01 Slide Hammer ^ J44685 Rear Axle Seal and Bearing Remover Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover and the gasket. 4. Remove the axle shaft. 5. Remove the axle shaft seal and/or the bearing from the axle housing using the J44685 (1) and the J2619-01 (2). Installation Procedure 1. Install the axle shaft bearing using the J23690 (1) and the J8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Page 2648 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Page 11671 40. If the vehicle is equipped with a sunroof, partially lower the headliner and disconnect the sunroof assembly electrical connector. 41. With the aid of an assistant, remove the headliner from the vehicle. Installation Procedure 1. With the aid of an assistant, install the headliner into the vehicle. 2. If the vehicle is equipped with a sunroof, partially raise the headliner and connect the sunroof assembly electrical connector. 3. With the aid of an assistant, fully raise the headliner Coupling Replacement - Antenna Inner and Coupling Replacement - Antenna Outer and install the left inboard sunshade retaining clip (5). 4. Install the right rear push pin (2) 5. Install the left rear push pin (3). 6. Install the assist handles to the roof panel. 7. Connect the electrical connector to the cellular phone antenna. 8. Connect the radio control module electrical connector to the right body side window. 9. Install the coat hooks to the roof panel. 10. Connect the radio antenna module electrical connector to the left body side window. 11. Install the upper rear quarter trim panels. 12. Connect the navigation antenna electrical connector, if equipped. 13. Connect the rain sensor electrical connector, if equipped. 14. Connect the inside rear view mirror electrical connector (6). 15. If the vehicle is NOT equipped with a sunroof, seat the 2 interlocking strips (1). Page 6900 Abbreviations And Meanings Part 15 Page 10028 Page 9053 Seat Belt Buckle: Service and Repair Buckle Replacement - Front REMOVAL PROCEDURE 1. Remove the front seat assembly. 2. Disconnect the seat belt reminder wiring harness (3) on the driver's seat. 3. Remove the nut (1) which retains the seat belt buckle to the seat assembly. 4. Remove the seat belt buckle from the seat assembly. INSTALLATION PROCEDURE 1. Install the seat belt buckle to the seat assembly. 2. Install the nut (1) which retains the seat belt buckle to the seat assembly. NOTE: Refer to Fastener Notice in Service Precautions. Page 3422 Muffler: Service and Repair Muffler Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the frame brace (required on extended versions). 3. Remove the nuts that secure the muffler to the catalytic converter pipe. Important: If there is damage to any part of the exhaust muffler assembly replace as an assembly. 4. Inspect the exhaust muffler and the front pipe of the exhaust muffler for any damage if it is to be reused. 5. Separate the muffler from the hanger insulators. 6. Remove the muffler. 7. If there is any damage aft of the exhaust muffler: 7.1. Suitably support the exhaust system. - Symptoms - Drive Belt Drive Belt: Testing and Inspection - Symptoms - Drive Belt Drive Belt Chirping See: Drive Belt Chirping Drive Belt Squeal See: Drive Belt Squeal Drive Belt Whine See: Drive Belt Whine Drive Belt Rumbling See: Drive Belt Rumbling Drive Belt Vibration See: Drive Belt Vibration Drive Belt Falls Off See: Drive Belt Falls Off Drive Belt Excessive Wear See: Drive Belt Excessive Wear Drive Belt Tensioner See: Drive Belt Tensioner/Testing and Inspection Page 5373 Disclaimer Audio System - Poor Radio Reception/Station Drifting Antenna Cable: All Technical Service Bulletins Audio System - Poor Radio Reception/Station Drifting Bulletin No.: 05-08-44-016A Date: March 15, 2006 TECHNICAL Subject: Poor Radio Reception or Radio Will Not Stay On Station (Check Antenna Coax Cable Connection and/or Install Antenna Cable Extension) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer SS 2004-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2006 GMC Envoy Denali, Envoy Denali XL 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Attention: Vehicles built after December 21, 2004 were produced with the radio antenna extension cable already installed. Use GMVIS to determine the vehicle build date. Supercede: This bulletin is being revised to add models and provide another cause for the condition. Please discard Corporate Bulletin Number 05-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on poor radio reception or that the radio will not hold the station. This occurs on either AM or FM bands. Cause The antenna coax cable connection behind the glove box door may not be fully seated or incorrect radio coax impedance. Correction Inspect the antenna coax cable connection and/or install an antenna extension cable, P/N 15267997, using the following procedure. 1. Remove the right closeout/insulator panel from the IP. 2. Verify that the antenna coax cable connection leads are fully seated. 3. If the leads are fully seated, separate the connection and install an antenna extension cable, P/N 15267997, between the two leads. 4. Install the right closeout/insulator panel to the IP. Parts Information Warranty Information (excluding Saab U.S. Models) Description and Operation Oil Change Reminder Lamp: Description and Operation GM OIL LIFE SYSTEM Your vehicle has a computer system that lets you know when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change will be indicated can vary considerably. For the oil life system to work properly, you must reset the system every time the oil is changed. When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. Either a "CHANGE ENGINE OIL" message in the Driver Information Center (DIC) or a CHANGE OIL indicator will come on. Change your oil as soon as possible within the next two times you stop for fuel. It is possible that, if you are driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, your engine oil and filter must be changed at least once a year and at this time the system must be reset. It is also important to check your oil regularly and keep it at the proper level. If the system is ever reset accidentally, you must change your oil at 3,000 miles (5 000 km) since your last oil change. Remember to reset the oil life system whenever the oil is changed. Page 13279 Abbreviations And Meanings Part 17 Page 9260 IMPORTANT: Ensure the inner and outer antenna couplings are aligned. - Do not touch the adhesive backing on the antenna coupling. 1. Align the outer antenna coupling to the inner antenna coupling. 2. Press firmly on all 4 corners and on the center of the antenna outer coupling (2) in order to ensure proper adhesion to the back glass (4). Hold pressure on the outer coupling (5) for 10-30 seconds. 3. Ensure that no gaps are present between the couplings (5, 2) and the back glass (4). Page 12945 Locations Electronic Components Page 1767 Registered And Non-Registered Trademarks Part 5 Page 242 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Specifications Wheel Hub: Specifications Wheel Hub and Bearing Mounting Bolts 77 ft. lbs. Wheel Hub Bolt 95 ft. lbs. Wheel Speed Sensor to the Wheel Hub and Bearing Mounting Bolt 13 ft. lbs. Page 10666 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 6494 Parking Brake Cable: Service and Repair Disabling the Park Brake Cable Automatic Adjuster Disabling the Park Brake Cable Automatic Adjuster 1. Place the park brake lever in the full release position. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Notice: Handling the parking brake cables during service requires extra care. Damage to the nylon coating reduces the corrosion protection. If the damage area passes through the nylon coating, increased parking brake effort could result. Avoid contacting the protective coating with sharp-edge tools or the sharp surfaces of the vehicle underbody. 3. Pull the park brake cable equalizer toward the rear of the vehicle and place a locking plier with protected jaws on the cable to hold the cable in an extended position. 4. Lower the vehicle. 5. Rotate the self-adjust clip into the lock position with a flat bladed tool. 6. Raise the vehicle. 7. Remove the locking plier from the park brake cable. 8. Lower the vehicle. 9. Partially raise the park brake lever, stopping prior to the self-adjust clip activating on the mount bracket tab. 10. Insert a flat bladed tool behind the self-adjust clip and twist the tool 90° to raise the self-adjust clip over the mount bracket tab. 11. Raise the handle until it is fully applied and remove the screwdriver. Page 1690 Page 11626 1. If replacing the roof retainer, install the roof retainer the roof panel ensuring the Z clips are fully seated. 2. If installing the existing roof retainer, position the roof retainer to the roof panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Partially install the 4 screws retaining the roof retainer to the Z clips. Tighten the roof retainer attachment screws to 1.2 N.m (10 lb in). 4. Install the headliner. Page 12449 Tighten Tighten the rear seat bracket mounting nuts to 25 N.m (18 lb ft). 5. Install the rear seat bracket trim covers (1). 6. Install the seat in the vehicle. Seat Cushion Replacement - Rear No. 1 SEAT CUSHION REPLACEMENT - REAR NO. 1 (TRAILBLAZER, ENVOY, BRAVADA) REMOVAL PROCEDURE 1. Remove the rear seat bracket trim cover. 2. Remove the hydraulic jack from the jack stowage area, on the left side only. 3. Position the seat cushion assembly in order to gain access to the 2 rear seat mounting nuts. 4. Remove the 2 mounting nuts. 5. Remove the seat cushion assembly from the vehicle. INSTALLATION PROCEDURE 1. Position the seat cushion assembly to the vehicle. 2. Install the 2 nuts that retain the seat cushion assembly to the floor panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat mounting nuts to 45 N.m (33 lb ft). 3. Install the hydraulic jack into the jack stowage area, on the left side only. 4. Adjust the seat cushion assembly to the latched position. 5. Install the rear mount trim cover. Audio System - Poor Radio Reception/Station Drifting Antenna Cable: Customer Interest Audio System - Poor Radio Reception/Station Drifting Bulletin No.: 05-08-44-016A Date: March 15, 2006 TECHNICAL Subject: Poor Radio Reception or Radio Will Not Stay On Station (Check Antenna Coax Cable Connection and/or Install Antenna Cable Extension) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer SS 2004-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2006 GMC Envoy Denali, Envoy Denali XL 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Attention: Vehicles built after December 21, 2004 were produced with the radio antenna extension cable already installed. Use GMVIS to determine the vehicle build date. Supercede: This bulletin is being revised to add models and provide another cause for the condition. Please discard Corporate Bulletin Number 05-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on poor radio reception or that the radio will not hold the station. This occurs on either AM or FM bands. Cause The antenna coax cable connection behind the glove box door may not be fully seated or incorrect radio coax impedance. Correction Inspect the antenna coax cable connection and/or install an antenna extension cable, P/N 15267997, using the following procedure. 1. Remove the right closeout/insulator panel from the IP. 2. Verify that the antenna coax cable connection leads are fully seated. 3. If the leads are fully seated, separate the connection and install an antenna extension cable, P/N 15267997, between the two leads. 4. Install the right closeout/insulator panel to the IP. Parts Information Warranty Information (excluding Saab U.S. Models) Page 612 Abbreviations And Meanings Part 24 Page 9898 Page 3560 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 884 Registered And Non-Registered Trademarks Part 3 Page 2001 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. ^ Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. Page 6270 6. Compress the front brake caliper piston. 6.1. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. 6.2. Slowly tighten the C-clamp until the piston pushes into the brake caliper enough to slide the brake caliper off the rotor. 6.3. Remove the C-clamp from the brake caliper. 7. Remove the lower mounting bolt from the slide pin. 8. Rotate the brake caliper upward until it stops. Page 261 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 4248 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 4165 Steps 25-28 Page 10319 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 13100 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: All Technical Service Bulletins Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 11269 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 824 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 161 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 10024 Specifications Compression Check: Specifications Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. Page 9910 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 8368 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 11623 12. Stake the other end of the retainer: 12.1. Remove the punch, part of J 41340. 12.2. Rotate the punch, part of J 41340, 180 degrees. 12.3. Hold the punch, part of J 41340, squarely against the end of the punch slot on J 41340. 12.4. Stake the metal over the other end of the retainer. 13. Loosen the holding screw. 14. Remove the cylinder from the J 41340. 15. Inspect that the retainer is properly staked. Restake as needed. 16. Lubricate the cylinder retainer slot. 17. Insert the following parts into the cylinder retainer slot: - The retainer spring (2) - The retainer (3) 18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed: - The detent pins (1) - The cylinder retainer (3) IMPORTANT:Use a paste type grease, not a spray, for the above step. SIDE DOOR LOCK CYLINDER CODING The side door lock cylinder has five snap-in tumblers. The number 1-5 positions (beginning closest to the cylinder head) is a brass retainer tumbler. The 6-10 positions are standard tumbler positions. Therefore, only the 6-10 positions are required. Overhead Console Replacement - Front Overhead Console Replacement - Front Page 7340 Fuse Block - Rear C3 Part 3 Locations Engine, Left Side Page 3098 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 12568 Heated Seat Element And Thermistor Assembly - Driver Back Page 11522 1. Install the steering gear crossmember. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the steering gear crossmember mounting bolts. Tighten the steering gear crossmember mounting bolts to 50 N.m (37 lb ft). 3. Install the rear lower control arm bracket to frame mounting bolts. Tighten the rear lower control arm bracket to frame mounting bolts to 240 N.m (177 lb ft). 4. Install the engine shield. 5. Install the engine shield mounting bolts. Tighten the engine shield mounting bolts to 25 N.m (18 lb ft). 6. Lower the vehicle. Page 4299 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Body - Revised Liftgate Lock Cylinder Replacement Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Body - Revised Liftgate Lock Cylinder Replacement Bulletin No.: 06-08-66-001 Date: February 14, 2006 SERVICE MANUAL UPDATE Subject: Revised Liftgate Lock Cylinder Replacement Models: 2004-2006 Buick Rainier Models 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2004 Oldsmobile Bravada 2005-2006 Saab 9-7X This bulletin is being issued to revise the Lock Cylinder Replacement - Liftgate procedure in the Body Rear End sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. When replacing the liftgate lock cylinder, removal of the rear window wiper motor, if equipped, is required. Lock Cylinder Replacement - Liftgate Removal Procedure 1. Remove the rear wiper motor. Refer to Wiper Motor Replacement - Rear. 2. Remove the lock rod from the lock cylinder. Page 9807 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 12900 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 13942 Abbreviations And Meanings Part 12 Page 11774 Page 4135 Abbreviations And Meanings Part 21 Specifications Wheel Hub: Specifications Wheel Hub and Bearing Mounting Bolts 77 ft. lbs. Wheel Hub Bolt 95 ft. lbs. Wheel Speed Sensor to the Wheel Hub and Bearing Mounting Bolt 13 ft. lbs. Page 4909 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 10629 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 5194 15. Install the 1-2 accumulator cover and the accumulator cover retaining bolts. ^ Tighten the accumulator cover retaining bolts to 11 Nm (97 inch lbs.). 16. Remove the J 25025-B from the transmission case. 17. Install the control valve body. 18. Install the transmission oil pan and filter. 19. Lower the vehicle. 20. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Page 7359 Fuse Block - Underhood C4 Part 2 Page 10824 Page 1448 Park/Neutral Position Switch (C2) Page 4853 Crankshaft Position (CKP) Sensor Page 9110 Seat Belt Switch-LF Page 12781 Page 6674 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 13096 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 11090 Front Door Weatherstrip: Service and Repair Weatherstrip Side Retainer Replacement Weatherstrip Side Retainer Replacement Removal Procedure 1. Open the front door. Remove the push pin retainers (2) from the front door sealing weatherstrip located at the base of the pillar. 2. Pull back the front door sealing weatherstrip (1) in order to expose the weatherstrip side retainer screws (2). 3. Remove the screws from the weatherstrip side retainer. 4. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer (2) to the windshield pillar. Electrical - Intermittent Interior Electrical Concerns Turn Signal Flasher: All Technical Service Bulletins Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 6133 Page 7845 4. Install the lower control arm to lower control am, bracket mounting bolts. Notice: Refer to Fastener Notice in Service Precautions. Important: Ensure that the lower control arm is parallel to the lower control arm bracket during the installation and tightening of the lower control arm mounting bolts and nuts. This will ensure correct alignment of the lower control arm bushings. 5. Install the lower control arm to lower control arm bracket mounting nuts. Tighten the nuts to 110 Nm (81 ft. lbs.). 6. Connect the shock module yoke to the lower control arm. 7. Install the shock module yoke lower mounting nut. Important: There is a washer between the stabilizer shaft link and the lower control arm made of herded steel and has a felt inner liner. Only replace this washer with an identical washer, standard washers should not be used. 8. Install the stabilizer shaft link and washer to the lower control arm. 9. Install the stabilizer shaft link retaining nut. Tighten the nut to 100 Nm (74 ft. lbs.). Diagrams Volume/AM/FM Switch (With RPO Code STW) Page 9675 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 12349 1. Position the memory seat switch to the lock and door lock and side window switch (1). 2. Connect the electrical connector (2) to the memory seat switch. 3. Install the door lock and side window switch (1). Verify that the front retaining clips and the rear retaining clips are fully seated. Page 249 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 3607 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 11615 8. Inspect for proper tumbler installation: 8.1. Hold the spring retainer (2) in position. 8.2. Insert the key (1) into the cylinder. 8.3. The side bar (3) should drop down flush with the cylinder diameter if properly installed. 8.4. Disassemble and assemble properly as needed. 9. Remove the key. 10. Secure the cylinder in the J 41340. 10.1. Inspect that the spring retainer is facing up and positioned directly under the punch slots. 10.2. Push the cylinder into the J 41340 until butted with the cylinder bezel. 10.3. Tighten the holding screw. 11. Stake the bezel end of the retainer in place: 11.1. Hold the flat side of the punch, part of J 41340, squarely against the face of the cylinder bezel. 11.2. Stake the lock cylinder metal over the retainer corners. Page 8244 AIR TEMPERATURE ACTUATOR REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the I/P carrier. 2. Remove the right side air temperature actuator retaining screws. 3. Disconnect the right side air temperature actuator electrical connector. 4. Remove the right side air temperature actuator. INSTALLATION PROCEDURE 1. Install the right side air temperature actuator. 2. Install the right side air temperature actuator retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the right side air temperature actuator electrical connector. 4. Install the I/P carrier. 5. Recalibrate the air temperature actuator on vehicles equipped with automatic climate control (C68), See: Testing and Inspection/Programming and Relearning Defroster Actuator DEFROSTER ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP carrier. Page 32 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 392 For vehicles repaired under warranty, use the table. Disclaimer Page 12924 Abbreviations And Meanings Part 13 Page 11173 Disclaimer Service Procedure 1. Ensure that the rear rocker panel in the tape contact area (1) is clean and dry. Use a non oil based cleaner, preferably isopropyl alcohol. For Chevrolet TrailBlazer EXT with molded-in-color rear rocker, coat the top of the rocker with adhesion promoter, P/N 12378462 (U.S.), 10953554 (Canada), or equivalent and then allow it to dry. 2. With the door closed, trace the contour of the door using a china marker or grease pencil. Hold the taper of the marker to the door as shown. Page 4491 Canister Purge Solenoid: Description and Operation EVAP PURGE SOLENOID The EVAP purge solenoid controls the flow of vapors from the EVAP system to the intake manifold. This normally closed solenoid is pulse width modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The solenoid will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system. Page 817 Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 3583 Powertrain Control Module (PCM) C2 Part 4 Page 8239 Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Install the air outlet duct to the console. 4. Install the screw to the air outlet duct. Tighten Tighten the screw to 1.9 N.m (17 lb in). 5. Install the console. Mode Actuator Auxiliary MODE ACTUATOR REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the mode actuator-auxiliary (1). 3. Remove the mode actuator-auxiliary (1) from the HVAC module-auxiliary. 4. Remove the retaining screws from the mode actuator-auxiliary. INSTALLATION PROCEDURE 1. Install the mode actuator (1) to the HVAC module-auxiliary. 2. Install the screws to the mode actuator-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Page 1402 Fuel Tank Pressure (FTP) Sensor Page 3949 Body Control Module (BCM) C1 Part 1 Page 11466 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Body - Liftgate Binding/Improper Fit/Rear Glass Broken Trunk / Liftgate Hinge: Customer Interest Body - Liftgate Binding/Improper Fit/Rear Glass Broken Bulletin No.: 06-08-66-011A Date: November 08, 2006 TECHNICAL Subject: Rear Liftgate Binds, Improper Fit, Broken Liftgate Glass (Install Welds and Bumpers) Models: 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL Supercede: This bulletin is being revised to add part number information. Please discard Corporate Bulletin Number 06-08-66-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the liftgate or the liftgate glass doesn't fit properly. In some extreme cases, the rear liftgate glass may have broken. Cause A couple of welds may have broken around the upper liftgate hinge(s) or a crack may have formed around the inner two welds. Remove the liftgate and inspect the inner to outer panel welds at the upper hinges. Correction Remove the liftgate trim and electrical wiring from the liftgate. Remove the liftgate and liftgate glass from the vehicle. Straighten the sheet metal at the hinges. Drill four 5/16" holes through the inner panel at the four locations shown in the illustration above. Prepare the sheet metal around the four holes for welding. Clamp the inner and out panel together. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 9080 1. Position the seat belt retractor bracket on the seat back frame. 2. Install the seat belt retractor bracket bolt (1) to the bracket and seat back frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt retractor bracket bolt to 55 N.m (40 lb ft). 3. Position the seat belt retractor assembly onto the seat back frame. 4. Install the push pin on the seat back retractor to the seat back frame. Page 2885 Page 6348 1. Lubricate the new piston seals (3), the caliper bores, and the pistons (2) using clean brake fluid. 2. Install the piston seals (3). Ensure that the piston seals are not twisted in the caliper bore grooves. 3. Install the boot seals (1) on the pistons (2). 4. install the pistons in the caliper bores. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the bleeder valve (5) in the caliper housing (6). ^ Tighten the bleeder valve to 7 Nm (62 inch lbs.). 6. Install the bleeder valve cap (4). 7. Install the boot seals into the caliper housing bores using the J 8092 and the J 43885. Rear Brake Caliper Overhaul - Rear Disassembly Procedure Caution: Refer to Brake Dust Caution in Service Precautions Caution: Refer to Brake Fluid Irritant Caution in Service Precautions Page 8623 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Page 6208 Abbreviations And Meanings Part 7 Page 9646 Page 13229 Oil Pressure Gauge: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 5592 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install TCC PWM solenoid retainer. Page 6716 3. Install the engine lift hook and secure the lift hook with 2 bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft). 4. Install the A/C line bracket to the lift hook and secure the bracket with the bolt. Tighten Tighten the A/C line bracket bolt to 10 N.m (89 lb in). 5. Install the drive belt. 6. Connect the battery negative cable. Page 9671 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 12172 Abbreviations And Meanings Part 17 Page 4416 Intake Air Temperature (IAT) Sensor Page 904 Body Control Module: Removal and Replacement Body Control Module Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the BCM on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. Page 13694 1. Position the sensor to the trim pad. 2. In order to install the sensor to the trim pad, rotate the sensor clockwise 1/4 turn. 3. Position the trim pad to the upper portion of the instrument panel (IP). 4. Connect the electrical connector to the sensor. 5. Remove the shop rags from the windshield defrost vents. 6. Install the trim pad to the IP. 7. Install the windshield garnish moldings. Page 122 Page 2646 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 12460 5. Remove the seat cushion panel from the pad and cover. 6. Remove the hog rings (1) from the seat cover. 7. Carefully separate the hook and loop fastener strips (2) holding the cover to the pad. 8. Remove the hog rings (1). INSTALLATION PROCEDURE 1. Install the hog rings (1) securing the seat cover to the pad. 2. Pull the cover over the pad pressing the hook and loop fastener strips (2) together. Page 9374 Abbreviations And Meanings Part 8 Page 9865 6. Connect the coaxial cable (1) to the inner antenna coupling. Page 2661 Drive Belt Falls Off Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. Page 12353 Power Seat Control Module: Diagrams Memory Seat Module - Driver C1 Page 3461 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 6344 10. Remove the brake caliper mounting bracket. 11. Remove the guide pin seals from the brake caliper mounting bracket. 12. Inspect the brake rotor. Installation Procedure 1. Install the guide pin seals on the mounting bracket. 2. If the guide pins and brake pad retaining clips are to be reused, use denatured alcohol to clean them. 3. Dry the brake guide pins and brake pad retaining clips with non-lubricated, filtered air. Page 2410 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 2821 Abbreviations And Meanings Part 19 Page 9987 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 10863 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 3852 Accelerator Pedal Position (APP) Sensor Page 8566 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Body - Liftgate Glass Unlatches On Bumpy Roads Tailgate Latch: Customer Interest Body - Liftgate Glass Unlatches On Bumpy Roads Bulletin No.: 04-08-66-004A Date: June 22, 2004 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Liftgate Glass Unlatches on Rough/Bumpy Road Surfaces (Replace Liftgate Window Latch) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to provide the correction and warranty information, which is now available for Advanced Service Bulletin Number 04-08-66-004. Please discard Corporate Bulletin Number 04-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the rear liftgate window unlatches when driving on rough/bumpy road surfaces. This condition may be very difficult to duplicate. Cause The liftgate window latch may be the cause of this condition. Correction Replace the liftgate window latch. Refer to the Liftgate Window Latch Replacement procedure in the Body Rear End sub-section of the Service Manual. Part Information Parts are expected to be available from GMSPO on June 25, 2004. Warranty Information For vehicles repaired under warranty, use the table. Page 9592 For vehicles repaired under warranty use, the table. Disclaimer Page 13274 Abbreviations And Meanings Part 12 Page 4819 Ignition Coil 3 Page 4258 Conversion - English/Metric Part 2 Page 1956 Disclaimer A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Recall 05V198000: Flasher Module Replacement Hazard Warning Flasher: Recalls Recall 05V198000: Flasher Module Replacement MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2004 Chevrolet/Trailblazer 2003-2004 GMC/Envoy 2003-2004 Isuzu/Ascender 2003-2004 Oldsmobile/Bravada 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V198000 RECALL DATE: April 29, 2005 COMPONENT: Exterior Lighting: Turn Signal POTENTIAL NUMBER OF UNITS AFFECTED: 286478 SUMMARY: On certain trucks and sport utility vehicles, the driver wishing to signal a turn by moving the directional signal lever, (up or down) may cause the front marker/turn lights and rear turn lights to flash in a manner similar to hazard warning, rather than flashing on the desired side only. CONSEQUENCE: The driver may not be able to clearly signal their intentions to turn, change travel lanes, or potentially warn others of an impaired vehicle operating condition increasing the risk of a crash. REMEDY: Dealers will replace the suspect flasher modules with a new flasher module designed with sealed relays and more durable contact material inside of the relays. The recall is expected to begin during August 2005. owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727, Buick at 1-866-608-8080, and Oldsmobile at 1-800-630-6537. NOTES: GM recall No. 05044. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Page 10634 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Procedures Carpet: Procedures Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 12378554, US ACDelco 88900909, Canadian P/N 88901678, may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a persistent or recurring odor, you may call to obtain additional information and usage suggestions. - In the USA, call 1-800-955-8591. - In Canada, call 1-800-977-4145. Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Interior - Elimination Of Unwanted Odors Carpet: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 6433 Disclaimer Service Procedure Tools Required (for brake pipe replacement, if required) J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent J 35589-A Brake Pressure Bleeder Adapter The following procedure provides instruction for inspecting, and if necessary, replacing the brake pipe located between the left front brake caliper flex hose and the ABS modulator. Inspection Procedure 1. Place the vehicle on a suitable hoist and turn the steering wheel to the full right. 2. Open the hood. 3. Raise and support the vehicle. 4. Clean and remove any dirt from the left front brake pipe and flare nut (3) where it connects to the left front caliper flex hose (4). 5. Carefully inspect the brake pipe where it goes into the flare nut for a tooling mark (1) as shown above. The mark may be located at any point around the circumference of the pipe and a mirror and flashlight may be required to see it. There will NOT be any of the spiral lines or grooves (2) in the tooling mark. ^ If the tooling mark IS present (1), then the brake pipe does NOT need to be replaced. Lower the vehicle and install the GM Recall Identification Label. Page 2726 8. Install the oil level indicator. 9. Remove the oil level indicator and check the oil level. Add oil if necessary. Check for any oil leaks. Page 3465 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 2107 Engine Oil: Description and Operation Api Oil and Additives WHAT KIND OF ENGINE OIL TO USE Oils recommended for your vehicle can be identified by looking for the starburst symbol. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). Do not use any oil which does not carry this starburst symbol. If you choose to perform the engine oil change service yourself, be sure the oil you use has the starburst symbol on the front of the oil container. If you have your oil changed for you, be sure the oil put into your engine is American Petroleum Institute certified for gasoline engines. You should also use the proper viscosity oil for your vehicle, as shown in the viscosity chart. As in the chart shown previously, SAE 5W-30 is the only viscosity grade recommended for your vehicle. You should look for and use only oils which have the API Starburst symbol and which are also identified as SAE 5W-30. If you cannot find such SAE 5W-30 oils, you can use an SAE 10W-30 oil which has the API Starburst symbol, if it's going to be 0°F (-18°C) or above. Do not use other viscosity grade oils, such as SAE 10W-40 or SAE 20W-50 under any conditions. NOTICE: Use only engine oil with the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench® oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. ENGINE OIL ADDITIVES Don't add anything to your oil. The recommended oils with the starburst symbol are all you will need for good performance and engine protection. Service and Repair Axle Shaft Assembly: Service and Repair Rear Axle Shaft Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the rear axle housing cover and the gasket. 5. Remove the pinion shaft locking bolt. 6. On axles without a locking differential, remove the pinion shaft. 7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing. Page 5155 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Page 9559 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 9361 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 12818 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 11032 9. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge. INSTALLATION PROCEDURE 1. Position the service hinge (1) within the scribe marks (2) on the hinge pillar (3). 2. Mark each hole location on the hinge pillar according to the service hinge. 3. Drill a 3 mm (1/8 in.) pilot hole at each marked location (1). Page 2911 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 8042 ^ Always inspect and adjust the pressure when the tires are cold. ^ Vehicles that have different pressures for the front and the rear need to be adjusted after tire rotation. Improper tire inflation may result in any or all of the following conditions: ^ Premature tire wear ^ Harsh ride ^ Excessive road noise ^ Poor handling ^ Reduced fuel economy ^ Low Tire Pressure Monitor (TPM) Light ON ^ Low Tire Pressure Message on the Drivers Information Center (DIC) Disclaimer Page 10645 Air Spring Sensor Calibration Air Spring: Service and Repair Air Spring Sensor Calibration Rear Air Spring Level Sensor Calibration 1. Raise and support the vehicle. 2. Remove the rear tire and wheels. 3. Lower the vehicle with the rear axle supported by the jackstands. 4. Raise or lower the vehicle until the D-height measurement is 25 mm (1 in) above the published D-height specification 160 mm (6.33 in). 5. Turn the ignition key to the ON position. This will partially deflate the air spring. 6. After two minutes, turn the ignition key to the OFF position and remove the air suspension fuse. Important: A D-height gauge block (1) can be used to determine the D-height position. Create a D-height gauge block using metal stock to 20 mm X 30 mm X the published D-height specification 135 mm (5.33 in). Use the block (1) as a measuring device only. 7. Raise or lower the vehicle so that the left side D-height is at a published specification 135 mm (5.33 in). Page 6185 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 6623 Positive: Service and Repair BATTERY POSITIVE CABLE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the battery negative cable. 2. Disconnect the battery positive cable from the battery. 3. Disconnect the harness from the engine harness bracket (2). 4. Disconnect the positive cable lead from the starter (1). 5. Disconnect the positive cable lead from the junction block (1). Page 8205 Air Door Actuator / Motor: Locations HVAC Sytem - Automatic Instrument Panel Carrier Page 12533 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 6565 Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. 1. Remove the air cleaner intake duct. 2. Disconnect the electrical connector from the fluid level sensor. 3. Using a pair of needle nose pliers, compress the locking tabs on the fluid level sensor Page 11713 Installation Procedure 1. Install the garnish molding to the vehicle. 2. Install the seat belt retractor to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the seat belt anchor to the body. Tighten the anchor bolt to 70 N.m (52 lb ft). Garnish Molding Replacement - Body Side Window - Rear (TrailBlazer EXT, Envoy XL) Garnish Molding Replacement - Body Side Window - Rear (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the bolt that retains the seat belt upper anchor to the body. 2. Remove the garnish molding from the vehicle. Installation Procedure 1. Install the garnish molding to the vehicle. 2. Install the seat belt retractor to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the seat belt anchor to the body. Tighten the anchor bolt to 70 N.m (52 lb ft). Garnish Molding Replacement - Center Pillar Garnish Molding Replacement - Center Pillar Removal Procedure Page 11777 Page 11099 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer Removal Procedure 1. Remove the screw that retains the sealing strip to the door. 2. Lift upward on the rear edge of the sealing strip. 3. Remove the sealing strip from the pinch-weld flange. Installation Procedure 1. Install the sealing strip to the pinch-weld flange, starting at the forward edge of the door. 2. Ensure that the sealing strip is fully seated to the pinch-weld flange. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the sealing strip to the door. Tighten the screw to 1.2 N.m (10 lb in). Page 12040 WA9260/74 - WA9539/47 Page 1372 Camshaft Position (CMP) Sensor Page 12512 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Recall - Spark Plug Misfire Condition Spark Plug: Recalls Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Page 12127 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 10032 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 1223 Air Temperature Sensor-Lower Right Page 12894 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 10390 Steps 1-6 Page 10505 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 1109 Power Seat Motor Position Sensor: Diagrams Position Sensor - Front Motor (w/Memory) Page 3647 Knock Sensor (KS) 2 Front Page 439 Page 9826 Abbreviations And Meanings Part 18 Page 11719 1. Remove the cargo shade/cover. 2. Remove the inflator access panel. 3. Remove the right rear quarter upper trim panel. 4. Remove the liftgate sill plate. 5. Remove the right rear door sill panel. 6. Remove the lower seat belt anchor bolt. 7. Release the retaining clips that retain the trim panel to the body. 8. Partially remove the trim panel in order to remove the inflator switch from the inflator bezel. 9. Remove the auxiliary air outlet washer and retaining nut. 10. Feed the auxiliary air outlet through the inflator bezel. 11. Remove the inflator bezel from the trim panel. 12. Disconnect the the 12-volt power supply electrical connector. 13. Remove the 12-volt power supply. 14. Remove the trim panel from the vehicle. INSTALLATION PROCEDURE Locations Instrument Panel Page 1804 Rear Window Wiper/Washer Switch (Chevrolet) Page 1178 Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Remove the accessory trim plate. 2. Disconnect the electrical connector from the traction control switch. 3. Release the traction control switch locking tabs located behind the trim plate. 4. Remove the traction control switch from the trim plate Installation Procedure 1. Position the traction control switch to the trim plate 2. Install the traction control switch to the instrument panel trim plate by seating the locking tabs. 3. Connect the electrical connector to the traction control switch. 4. Install the accessory trim plate. Page 6749 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 2036 2. Install the evaporator tube. Notice: Refer to Fastener Notice in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Vehicle Damage Warnings 3. Connect the evaporator tube to the evaporator (5). Tighten Tighten the nut to 28 N.m (21 lb ft). 4. Connect the auxiliary evaporator tube to the auxiliary piping. Tighten Tighten the nut to 28 N.m (21 lb ft). 5. Connect the evaporator tube to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). 6. Install the coolant recovery tank. 7. Install the washer solvent container. 8. Install the nuts (1, 2) retaining the evaporator tube to the fender. Tighten Tighten the nuts to 28 N.m (21 lb ft). 9. Evacuate and recharge the A/C system. 10. Leak test the fittings of the components using the J 39400. Page 1017 32. Install the new hose (1), # 1005 (L6 engine) or# 1006 (V8 engine) onto the coolant bypass valve at the location the above hose was removed. The other end of this hose will be installed on the auxiliary heater pump outlet port. Page 10215 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 605 Abbreviations And Meanings Part 17 Page 1324 Turn Signal/Mutifunction Switch C2 Page 13822 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13238 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 12409 1. Remove the 3 screws that retain the switch bezel to the seat. 2. Partially remove the switch bezel from the seat. 3. Remove the seat switches from the switch bezel by releasing the retaining tabs. 4. Remove the lumbar switch from the switch bezel by releasing the retaining tabs. 5. Remove the switch bezel from the seat. INSTALLATION PROCEDURE 1. Install the lumbar switch to the switch bezel, verifying that the retaining tabs are fully seated. Page 1378 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Page 12048 WA160E/06 - WA228A/55 Page 6709 Registered And Non-Registered Trademarks Part 5 Page 714 Part 2 of 2 Page 4137 Abbreviations And Meanings Part 23 Page 3622 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 4969 6. Remove the 1-2 and 2-3 Shift solenoid retainers. 7. Remove the 1-2 and 2-3 Shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 7335 Fuse Block - Rear C2 Part 4 Page 13651 4. Position the lens to the headliner with the horizontal tab facing forward. 5. Position the horizontal tab above the headliner and push the lens forward to seat the tab. 6. Push upward on the rear portion of the lens, in order to seat the rear lens retaining tab. 7. Pull down on the lens to ensure that the lens is secured to the headliner. Page 2908 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 3275 Fan Shroud: Service and Repair Cooling Fan and Shroud Replacement Tools Required J 41240 Fan Clutch Remover and Installer - J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the air intake baffle. 2. Remove the hood latch support. 3. Disconnect the transmission cooler lines at the engine and release the lines from the fan shroud. 4. Remove the 2 upper bolts on the fan shroud. 5. Reposition the upper inlet radiator hose clamp using J 38185. 6. Remove the upper inlet radiator hose from the radiator. 7. Remove the electrical connector from the shroud. 8. Position the water pump so the bolts are aligned in the vertical. 9. Remove the fan hub nut from the water pump shaft in a counterclockwise rotation. Using the J 46406, in order to secure the water pump pulley, loosen the cooling fan hub nut from the water pump shaft. Page 4142 Registered And Non-Registered Trademarks Part 2 Page 10823 Page 7451 For vehicles repaired under warranty, use the table. Disclaimer Page 836 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 13980 Steps 13-14 Temperature Displays SC or OC - Mirrors MIRRORS - TEMPERATURE DISPLAYS SC OR OC Page 11003 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 12935 Abbreviations And Meanings Part 24 Page 6932 Application Table Part 2 Page 808 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Page 4787 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Page 2662 Drive Belt Squeal Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt(s) or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. 5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Drive Belt Vibration Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Page 2179 5. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 6. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. Page 8920 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Page 329 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 10387 Steps 1-4 Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 10432 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 8358 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 7518 7. Remove the junction block bracket retaining bolts (1) and remove the junction block bracket from the vehicle. INSTALLATION PROCEDURE 1. Position the junction block bracket and install the bolts (1). Tighten Tighten the junction block bracket bolts to 6 N.m (53 lb in). 2. Align the wiring harnesses and install the fuse relay center. 3. Install the fuse relay center bolts (3). Tighten Tighten the relay center bolts to 6 N.m (53 lb in). Page 877 Abbreviations And Meanings Part 22 Page 2683 6. Remove the right and the left upper engine mount nuts. 7. Raise the vehicle. Refer to Vehicle Lifting. 8. Remove the right and the left lower engine mount nuts. 9. Remove the engine protection shield mounting bolts. 10. Remove the engine protection shield. Important: When placing jack onto the oil pan, pay close attention to not damaging the oil level sender. 11. Lower the vehicle and place a floor jack under the oil pan with a block of wood. 12. Raise the engine with the jack just enough to clear the engine mount studs. 13. Remove the right engine mount from the bracket. Page 6711 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 130 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Body - Revised Liftgate Lock Cylinder Replacement Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Body - Revised Liftgate Lock Cylinder Replacement Bulletin No.: 06-08-66-001 Date: February 14, 2006 SERVICE MANUAL UPDATE Subject: Revised Liftgate Lock Cylinder Replacement Models: 2004-2006 Buick Rainier Models 2002-2006 Chevrolet TrailBlazer Models 2002-2006 GMC Envoy Models 2004 Oldsmobile Bravada 2005-2006 Saab 9-7X This bulletin is being issued to revise the Lock Cylinder Replacement - Liftgate procedure in the Body Rear End sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. When replacing the liftgate lock cylinder, removal of the rear window wiper motor, if equipped, is required. Lock Cylinder Replacement - Liftgate Removal Procedure 1. Remove the rear wiper motor. Refer to Wiper Motor Replacement - Rear. 2. Remove the lock rod from the lock cylinder. Page 4077 Page 9160 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 4885 Parts are currently available from GMSPO. Disclaimer Campaign - Fuel Tank Reservoir Corrosion Warranty Ext. Technical Service Bulletin # 07076A Date: 081105 Campaign - Fuel Tank Reservoir Corrosion Warranty Ext. SPECIAL COVERAGE Bulletin No.: 07076A Date: November 05, 2008 Subject: 07076A - SPECIAL COVERAGE ADJUSTMENT - FUEL TANK MODULAR RESERVOIR ASSEMBLY CORROSION Models Supercede: The ending breakpoints for the 2002 Chevrolet TrailBlazer and the 2003 Chevrolet TrailBlazer EXT have been revised. Please discard all copies of bulletin 07076, issued September 2008. Condition Page 12943 Registered And Non-Registered Trademarks Part 6 Page 4302 Body Control Module (BCM) C1 Part 1 Suspension - Front/Rear Suspension Pop/Clunk/Snap Noises Stabilizer Link: Customer Interest Suspension - Front/Rear Suspension Pop/Clunk/Snap Noises TECHNICAL Bulletin No.: 05-03-08-007A Date: March 31, 2008 Subject: Rattle, Clunk, Pop, Snap Noise from Front and/or Rear Suspension While Driving Over Rough, Uneven, Wash Board Road Surfaces (Replace Appropriate Stabilizer Link(s)) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to update the Warranty information. Please discard Corporate Bulletin Number 05-03-08-007 (Section 03 - Suspension). Condition Some customers may comment on a rattle, clunk, pop, loose lumber-type noise coming from the front and/or rear suspension while driving over rough uneven roads. Cause The front and/or rear stabilizer links, may develop additional clearance in the ball joint links leading to a noise concern. Correction 1. Road test the vehicle and verify if the noise is coming from the front or rear, left or right of the vehicle. It is possible in some circumstances that the noise may be coming from the front and rear suspension. 2. Once it is determined that the noise is coming from the front or rear, left or right of the vehicle, raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information (SI Document ID # 1253321). Caution: DO NOT DRIVE the vehicle on highways or at a high rate of speed while the stabilizer link(s) are removed/disconnected from the vehicle. ONLY test drive the vehicle in a parking lot or on a side street. Driving the vehicle with the link(s) removed/disconnected may reduce vehicle stability. 3. Remove or disconnect the suspect stabilizer link(s) from the appropriate stabilizer shaft and re-road test the vehicle with the links disconnected to verify the source of the noise. ^ If the noise is still present with the suspect link(s) removed the source of the noise is NOT the stabilizer links. Refer to the information below for diagnostic assistance. ^ Service Bulletin - Rattle From Front of Vehicle (Adjust Hood Latch Following New Procedure) # 03-08-63-003 or newer (SI Document ID # 1410372) ^ Service Bulletin - Rattle Noise Under Hood (Reposition Hood Prop Rod) # 04-08-63-005 or newer (SI Document ID # 1527265) ^ Service Information - Suspension - Suspension General Diagnosis in the appropriate SI Document. ^ If the noise is no longer present with the suspect stabilizer link(s) removed continue with the next step. 4. Replace the suspect stabilizer link(s) (see parts information below). Refer to the appropriate Service Information for the replacement procedure. Page 4393 operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. If installing the original sensor or a new sensor without sealant, apply thread sealer P/N 12346004 or equivalent. 2. Install the ECT sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 16 N.m (12 lb ft). 3. Connect the ECT electrical connector (1). 4. Install the generator and the drive belt. 5. Connect the negative battery terminal. 6. Refill the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. Page 12956 OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 7815 4. Disconnect the outer tie rod from the steering knuckle using J24319-B. Page 590 Abbreviations And Meanings Part 2 Page 2450 Disclaimer Page 11385 Optimal results will be obtained by allowing the seal to remain in a compressed state with the glass closed for a period of 48 hours. Parts Information Parts are expected to be available from GMSPO on June 13, 2003. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Page 1665 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Hood Latch Replacement Hood Latch: Service and Repair Hood Latch Replacement Hood Latch Replacement Removal Procedure 1. Remove the grille. 2. Using a grease pencil or other suitable marking device, mark the location of the latch on the mounting bracket. 3. Remove the bolts that attach the latch to the mounting bracket. 4. Disconnect the hood latch cable from the latch. 5. Remove the latch from the vehicle. Installation Procedure 1. Connect the hood latch cable to the latch. Page 3193 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water (if the water in your area is of poor quality, it is recommended you use distilled or de-ionized water) and DEX-COOL coolant will: - Give freezing protection down to -34°F (-37°C). - Give boiling protection up to 265°F (129°C). - Protect against rust and corrosion. - Help keep the proper engine temperature. - Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Page 2270 12. Disconnect the body wiring harness connector (1) from the junction block. 13. Disconnect the headliner harness connector (2) from the junction block. 14. Disconnect the console harness connector from the junction block. 15. Remove the block base retaining nuts from the floor studs. 16. Remove the block base from the floor panel. INSTALLATION PROCEDURE 1. Install the block base to the floor studs. 2. Install the block base retaining nuts to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the block base retaining nuts to 10 N.m (88 lb in). 3. Connect the console harness connector to the block base. 4. Connect the headliner harness connector (2) to the block base. 5. Connect the body wiring harness connector (1) to the block base. Page 10653 Page 7251 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 10897 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 9618 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 13012 Abbreviations And Meanings Part 13 Page 5556 2. Install the range selector cable (2) to the floor Shift control assembly. 3. Install the end of the range selector cable (1) to floor control ball stud. 4. Install the drivers side front mat and carpet. 5. Install the console. 6. Raise the vehicle. Refer to Vehicle Lifting. 7. Install the cable to the retainer (3) on the floor panel. If the vehicle is equipped with 4WD, install the cable to the retainers located on the transfer case. 8. Install the range selector cable (4) to the bracket (1). 9. Install the retainer (5) to the range selector cable. 10. Install the end of the range selector cable to the transmission range selector lever ball stud (6). 11. Adjust the range selector cable. 12. Lower the vehicle and check for proper operation. Page 10827 Brakes - Revised Caliper Mounting Bolt Torque Spec. Brake Caliper: Technical Service Bulletins Brakes - Revised Caliper Mounting Bolt Torque Spec. Bulletin No.: 03-05-23-002A Date: April 26, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Brake Caliper Bracket Mounting Bolt Fastener Tightening Specification Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer Models 2004-2005 Chevrolet SSR 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to add models, model years and update the fastener tightening specification. Please discard Corporate Bulletin Number 03-05-23-002 (Section 05 - Brakes). This bulletin is being issued to revise the front brake caliper bracket mounting bolt fastener tightening specification in the Disc Brakes sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The correct fastener tightening specification for the front brake caliper bracket mounting bolt is 150 N.m (110 lb ft). Disclaimer Page 9972 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Page 13569 Page 6895 Abbreviations And Meanings Part 10 A/C - Contaminated R134A Refrigerant Refrigerant: All Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Page 4607 Fuel Injector 2 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Locations Seat Belt Buckle Page 2634 14. Remove the valve spring retainer and the valve 15. Use the J 38320 and remove the seals. 16. Clean and inspect the cylinder head. Installation Procedure Important: Lubricate the valve stems with clean engine oil before installing. 1. Use the J 33820 to install the valve seals. There is only one size seal. Page 4096 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 4857 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor harness connector. 3. Remove the CKP sensor retaining bolt. 4. Remove the CKP sensor from the engine block. INSTALLATION PROCEDURE IMPORTANT: Inspect the sensor O-ring for the following conditions: Any wear - Any cracks - Any leakage Replace the O-ring if necessary. Lubricate the new O-ring with engine oil before installation. 1. Install the CKP sensor into the engine block. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 10 N.m (89 lb in). 2. Install the CKP sensor retaining bolt. 3. Connect the CKP sensor harness connector. 4. Lower the vehicle. 5. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 2747 Oil Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Remove the A/C compressor bottom bolts (4) and loosen the top bolts (2, 3). 2. Remove the oil level indicator and tube. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove left and right front tire and wheel assemblies. 5. Remove the engine protection shield mounting bolts. 6. Remove the engine protection shield. 7. Remove the steering gear crossmember, front. 8. Remove the left and right wheel drive shaft. 9. Remove the front drive axle clutch fork assembly. Page 4423 Knock Sensor (KS) 2 Front Page 10489 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 2164 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Rear Axle Housing Cover and Gasket Replacement Seals and Gaskets: Service and Repair Rear Axle Housing Cover and Gasket Replacement Rear Axle Housing Cover and Gasket Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the rear axle. 3. Remove the rear axle housing cover bolts (1). Important: Do not nick or cut the rear axle housing cover gasket. 4. Remove the rear axle housing cover (2) from the axle housing. 5. Drain the axle lubricant into a suitable container. Installation Procedure 1. Inspect the rear axle cover gasket for nicks, cuts or damage that may cause the gasket to not seal properly. If any of these conditions exist, replace the gasket. 2. If the gasket is to be reused, clean the rear axle housing cover gasket a suitable cleaner. 3. Clean the rear axle housing cover gasket surface and the rear axle housing gasket surface with a suitable cleaner. 4. Install the rear axle housing cover gasket and the rear axle housing cover (2). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the rear axle housing cover bolts (1). ^ For the 8.0 inch axle, tighten the rear axle housing cover bolts in a crosswise pattern to 30 Nm (20 ft. lbs.). ^ For the 8.6 inch axle, tighten the rear axle housing cover bolts in a crosswise pattern to 25 Nm (18 ft. lbs.). 6. Fill the rear axle with axle lubricant. Use the proper fluid. 7. Lower the vehicle. Refer to Vehicle Lifting. Testing and Inspection Oil Level Warning Indicator: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Page 11722 3. Index the locating tabs on the trim panel to the holes in the body. 4. Connect the wiring harness connector to the auxiliary power outlet. 5. Install the five screws that the retain the rear quarter trim panel to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear quarter trim panel screws to 2.5 N.m (22 lb in). 6. Install the seat belt lower anchor. Tighten Tighten the seat belt anchor bolt to 70 N.m (52 lb ft). 7. Install the right rear door sill panel. 8. Install the liftgate sill plate. 9. Install the right body side window forward garnish molding. 10. Install the right body side window rear garnish molding. 11. Return the third row seats to the upright position. 12. Install the cargo shelf. Trim Panel Replacement - Rear Quarter - Left (TrailBlazer EXT, Envoy XL) Trim Panel Replacement - Rear Quarter - Left (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the cargo shelf. 2. Tumble the third row seats to the cargo position. 3. Remove the left body side window rear garnish molding.. 4. Remove the left body side window forward garnish molding. 5. Remove the liftgate sill plate. 6. Remove the left rear door sill panel. 7. Remove the lower seat belt anchor bolt. 8. Remove the auxiliary power outlet from the trim panel. Page 13966 Heated Glass Element: Electrical Diagrams Defogger Diagram Page 691 Sunroof Module C2 Page 11708 Trim Panel: Service and Repair Garnish Molding Replacement - Body Side Window - Front GARNISH MOLDING REPLACEMENT - BODY SIDE WINDOW - FRONT (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE 1. Remove the bolt that retains the seat belt upper anchor to the body. 2. Remove the garnish molding from the vehicle. INSTALLATION PROCEDURE 1. Install the garnish molding to the vehicle. 2. Install the seat belt retractor to the body. 3. Install the bolt that retains the seat belt anchor to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the anchor bolt to 70 N.m (52 lb ft). Garnish Molding Replacement - Body Side Window - Rear GARNISH MOLDING REPLACEMENT - BODY SIDE WINDOW - REAR (TRAILBLAZER EXT, ENVOY XL) REMOVAL PROCEDURE Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 13422 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Recall - Windshield Wiper Defect Technical Service Bulletin # 04005 Date: 040701 Recall - Windshield Wiper Defect File In Section: Product Recalls Bulletin No.: 04005 Date: July, 2004 PRODUCT SAFETY RECALL SUBJECT: WINDSHIELD WIPER OPERATION MODELS: 2002-2003 CHEVROLET TRAILBLAZER, TRAILBLAZER EXT 2002-2003 GMC ENVOY, ENVOY XL 2002-2003 OLDSMOBILE BRAVADA CONDITION General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002 and 2003 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and Oldsmobile Bravada vehicles. Under certain conditions, water may seep into the windshield wiper module. If this were to happen, it could result in windshield wipers that will not turn on, cease operation while driving, fail to turn off, turn on by themselves, and/or continuous windshield washer pump operation. Improper operation of the windshield wiper system in a severe weather situation could reduce the driver's visibility, resulting in a possible vehicle crash without prior warning. CORRECTION Dealers are to inspect and seal the windshield wiper motor. In some cases, the windshield wiper module may require replacement. VEHICLES INVOLVED Involved are certain 2002 and 2003 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. Page 12292 Sunroof Switch Page 12906 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 10374 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 11984 Parts Information Repair Claim Information - Refer to the extent of the repair instructions as approved by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) Warranty Information (excluding Saab U.S. Models) Page 12302 1. Attach the mechanic's wire to the drain hose. 2. Route the end of the drain hose through side cowl panel until the paint mark is visible, right or left side, as needed. 3. Install the 2 hose clips securing the drain hose to the side door frame, right or left side, as needed. 4. Install the 2 hose clips securing the drain hose to the cowl panel, right or left side, as needed. 5. Connect the front sunroof drain hose to the sunroof module front spigot, right or left side, as needed. 6. Install the headliner. Page 3870 Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 13937 Abbreviations And Meanings Part 7 Page 11052 2. Install the outside handle lock rods to the latch as previously noted. 3. Install the inside handle lock rods to the latch as previously noted. 4. Position the latch in order to connect the electrical connectors as needed. 5. Install the latch to the door. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the 3 screws that retain the latch to the door. Tighten the screws to 10 N.m (22 lb in). 7. Install the inside door handle. 8. Connect the lock cylinder rod to the cylinder, if equipped. 9. Install the lock rod to the outside door handle. 10. Connect the lock rod retaining clip to the outside door handle. 11. Install the water deflector. 12. Install the door trim panel. Page 6744 Disclaimer Page 2263 Location View Page 5413 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Page 6988 Application Table Part 2 Page 8376 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Press tabs (1) inward and lift to remove the junction block cover. 3. Pull upward on the fuse relay center cover (1) to release the retaining tabs and remove the cover. 4. Note the location and remove the harness end bolts (2) and remove the harness ends from the fuse relay center. 5. Remove the fuse relay center bolts (3) and remove the fuse relay center from the junction block bracket. 6. Pull downward on the wiring harness ends to remove from the bottom of the fuse relay center. Locations Engine, Right Front Page 2085 8. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 5505 3. Install the 1-2 and 2-3 Shift solenoids. 4. Install the 1-2 and 2-3 Shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. 9. Install the transmission oil pan and filter. Page 4245 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 8103 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 66 Abbreviations And Meanings Part 11 Page 4525 Steps 4-7 Page 12135 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 11709 1. Remove the bolt that retains the seat belt upper anchor to the body. 2. Remove the garnish molding from the vehicle. INSTALLATION PROCEDURE 1. Install the garnish molding to the vehicle. 2. Install the seat belt retractor to the body. 3. Install the bolt that retains the seat belt anchor to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the anchor bolt to 70 N.m (52 lb ft). Garnish Molding Replacement - Center Pillar GARNISH MOLDING REPLACEMENT - CENTER PILLAR REMOVAL PROCEDURE Page 433 Page 11189 Rear Door Panel: Service and Repair Water Deflector Water Deflector Replacement - Rear Door Removal Procedure 1. Open the door. 2. Remove the door trim panel. 3. Carefully remove the water deflector from the door by releasing the adhesive backing. Installation Procedure 1. Position the water deflector to the door. 2. Press the water deflector to the door. Ensure that the water deflector forms a proper seal around the surface of the door panel. 3. Install the door trim panel. Page 2327 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Page 2799 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 5783 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector.Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON transmission fluid. Page 12939 Registered And Non-Registered Trademarks Part 2 Locations Steering Column Page 13985 Heated Glass Element: Component Tests and General Diagnostics DEFOGGER GRID LINES DIAGNOSIS 1. Start the engine. 2. Activate the rear window defogger system. 3. Connect a test lamp to a good ground. 4. Move the test lamp probe from zone 5 to zone 1 along each grid line. - If the test lamp shows full brilliance at both ends of the grid lines. Inspect for an open or poor connection in the ground circuit of the rear window defogger grid. - If the test lamp goes out, test the grid line in at least 2 places (1,3) to eliminate the possibility of bridging the open (2) in the grid line. IMPORTANT: The test lamp brilliance will decrease proportionately to the increased resistance in the grid line as the probe is moved from the battery positive bus wire to the ground bus wire. The test lamp brilliance may vary from one window to another. 5. Once the open (2) is located, repair the grid line. Refer to Grid Line Repair. Description and Operation Air Cleaner Restriction Indicator: Description and Operation The air cleaner restriction indicator is located on the intake duct between the air cleaner assembly and the throttle body. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Keyless Entry - System Inoperative Door Module: All Technical Service Bulletins Keyless Entry - System Inoperative Bulletin No.: 03-08-52-002 Date: March 27, 2003 TECHNICAL Subject: Remote Keyless Entry Inoperative (Reprogram Liftgate Module) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the Remote Keyless Entry (RKE) is inoperative at times. Cause An anomaly has been identified with the software in the Liftgate Module (RKE functions). The Liftgate Module software is affected when the temperature is approximately 40°C (104°F). Correction Using normal SPS reprogramming procedures, reprogram the LGM Liftgate module. The information was released on TIS version 2.75 or newer broadcast in March 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6016 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Service and Repair Catalyst Shield: Service and Repair Catalytic Converter Heat Shield Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the 5 bolts securing the heat shield to the floor panel studs. 3. Remove the heat shield from the vehicle. Installation Procedure 1. Place the catalytic converter heat shield onto the floor panel studs. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Secure the heat shield with the 5 bolts. Tighten the catalytic converter heat shield bolts to 7 Nm (62 inch lbs.). 3. Lower the vehicle. Page 794 4. Install the harness end bolts (2). 5. Install the fuse relay center cover (1) over the relay center bolts. Press downward to engage the tabs. 6. Install the junction block cover. Press downward to engage the tabs. Page 10840 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 1814 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Page 4578 Fuel: Specifications GASOLINE OCTANE Use regular unleaded gasoline with a posted octane of 87 or higher. If the octane is less than 87, you may get a heavy knocking noise when you drive. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. Otherwise, you might damage your engine. A little pinging noise when you accelerate or drive uphill is considered normal. This does not indicate a problem exists or that a higher-octane fuel is necessary. If you are using 87 octane or higher-octane fuel and you hear heavy knocking, your engine needs service. ADDITIVES To provide cleaner air, all gasoline in the United States are now required to contain additives that will help prevent engine and fuel system deposits from forming, allowing your emission control system to work properly. You should not have to add anything to your fuel. Gasoline containing oxygenates, such as ethers and ethanol, and reformulated gasoline may be available in your area to contribute to clean air. General Motors recommends that you use these gasoline, particularly if they comply with the specifications described earlier. NOTICE: Your vehicle was not designed for fuel that contains methanol. Don't use fuel containing methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber parts. That damage wouldn't be covered under your warranty. Some gasoline that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such gasoline. Fuels containing MMT can reduce the life of spark plugs and the performance of the emission control system may be affected. The malfunction indicator lamp may turn on. If this occurs, return to your authorized GM dealer for service. CALIFORNIA FUEL If your vehicle is certified to meet California Emission Standards (see the underhood emission control label), it is designed to operate on fuels that meet California specifications. If this fuel is not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The malfunction indicator lamp may turn on (see Malfunction Indicator Lamp ) and your vehicle may fail a smog-check test. If this occurs, return to your authorized GM dealer for diagnosis. If it is determined that the condition is caused by the type of fuel used, repairs may not be covered by your warranty. Service and Repair Radiator Support: Service and Repair Brace Replacement - Radiator Support Diagonal Removal Procedure 1. Remove the bolts that retain the radiator support diagonal brace to the radiator support. 2. Remove the radiator support diagonal brace from the vehicle. Installation Procedure 1. Install the radiator support diagonal brace to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the radiator support diagonal brace to the radiator support. Tighten the radiator support diagonal brace to 25 N.m (18 lb ft). Page 9280 1. Position the radio extension cable to the IP support bars as previously noted. 2. Reach through the IP compartment to connect the antenna cable to the radio. 3. Install the radio extension cable attachments (1) to the IP support bars. 4. Connect the antenna cable (2) to the radio extension cable. 5. Install the inflatable restraint module. Page 8665 Housing Assembly HVAC: Service and Repair HVAC Module Pass Thru Seal - Auxiliary HVAC MODULE PASS THRU SEAL REPLACEMENT - AUXILIARY TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the HVAC Module-Auxiliary. 2. Remove the screws from the heater core cover-auxiliary. 3. Remove the heater core cover-auxiliary. 4. Remove the HVAC pass thru seal (3) from the HVAC module-auxiliary (1). INSTALLATION PROCEDURE 1. Install the HVAC pass thru seal (3) to the HVAC module-auxiliary (1). 2. Install the heater core cover-auxiliary. 3. Install the screws to the heater core cover-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to .....1.9 N.m (18 lb in). 4. Install the HVAC Module-Auxiliary. Page 11652 2. Starting with position 1, insert the tumblers (4) into their corresponding slots in the coded order. 3. Using your fingers, pull out the side bar (3) until the tumblers fall completely into place. 4. Insert one tumbler spring (2) above each tumbler (4). 5. Lubricate the tumblers using Superlube(r) GM P/N 12346241 or equivalent. 6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder. 7. Press down the retainer (1) until fully seated in the depression. Page 12278 Important: Midway through the rotation cycle, the tool will move further into the access hole. 6. Push upward on the tool while rotating the sunshade parallel to the windshield. The sunshade pivot arm bezel should appear to be recessed into the bezel. Important: Ensure the pivot arm is recessed into the bezel before removing the sunshade from the headliner. 7. Apply outboard pressure to the sunshade while the sunshade is parallel to the windshield. 8. Pull the sunshade downward while maintaining outboard pressure to the sunshade. You will notice a separation between the headliner and the sunshade bezel. 9. In order to remove the sunshade from the headliner, carefully grab the headliner at the windshield pillar area and apply downward pressure while gently rocking the sunshade up and down. Page 3162 34. Install the coolant bypass valve to its original location and secure with a nut. 35. Connect the other end of the new hose from step 29 to the outlet port of the auxiliary heater pump. 36. Connect the vacuum hose to the coolant bypass valve. 37. Connect the coolant bypass valve hose to the auxiliary rear heater line. 38. Install the heater hose quick connect retainers to the heater core pipes. 39. Connect the remaining two hoses to the heater core. 40. Install the new auxiliary heater pump wiring harness to the vehicle. Page 3330 Disclaimer Recall 04V046000: Erratic Wiper Operation Wiper Control Module: All Technical Service Bulletins Recall 04V046000: Erratic Wiper Operation DEFECT: The windshield wipers on these sport utility vehicles may fail to turn on, unexpectedly stop working, fail to turn off/on by themselves (moisture sensitive wiper system), or the washer pump may operate continuously because water can enter the wiper module and either cause a short circuit or corrosion of components within the module. Driver visibility could be reduced, which could result in a crash. REMEDY: Dealers will cover the windshield wiper module vent hole with a patch. Also, the wiper motor, circuit board, and electrical connector will be inspected for signs of water intrusion and/or corrosion and be replaced as required. The manufacturer has reported that owner notification is expected to begin during the third quarter of 2004. Owners may contact Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Oldsmobile at 1-800-630-6537. Connector Views Fuse Block: Connector Views Fuse Block - Rear C1 Fuse Block - Rear C1 Part 1 Locations Engine, Left Side Page 11048 Notice: Refer to Fastener Notice in Service Precautions. 7. Align the hinge (1) and the backing plate (2) with the holes in the door (3). Tighten the 4 bolts to 25 N.m (18 lb ft). 8. Hand tighten all of the 4 supplied bolts (4). 9. Align the hinge. 10. Torque all of the 4 bolts. 11. Clean and prepare all bare-metal surfaces. 12. Apply a full-bodied caulk around the service hinge. 13. Refinish as necessary. 14. Install and align all of the related panels and components. Page 5460 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Page 13029 Registered And Non-Registered Trademarks Part 4 Page 6755 Locations Page 13914 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 4263 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Service and Repair Blower Motor Relay: Service and Repair BLOWER MOTOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover of the under hood fuse block. 2. Remove the blower motor relay (1) from the under hood fuse block (2). INSTALLATION PROCEDURE 1. Install the blower motor relay (1) to the under hood fuse block. 2. Install the cover of the under hood fuse block. Page 11457 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 3046 Steps 8-9 Page 5139 10. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Page 10282 Speaker - RF I/P (With RPO Code UQA) Page 4651 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the fuel pressure service connection cap. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Install the fuel tank shield if removed. Page 6822 Abbreviations And Meanings Part 26 Service Precautions Hose/Line HVAC: Service Precautions CAUTION: DO NOT REMOVE HOSES OR LINES BEFORE SYSTEM IS FULLY DISCHARGED. MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED. Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter and Bypass Valve Assembly Replacement Removal Procedure 1. Remove the oil filter. 2. Remove the oil filter adapter. 3. Remove the oil filter bypass valve. Installation Procedure 1. Install the oil filter bypass valve. Page 10331 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 11827 Abbreviations And Meanings Part 12 Page 13285 Abbreviations And Meanings Part 23 Page 4132 Abbreviations And Meanings Part 18 Page 11728 Trim Panel Replacement - Rear Quarter Upper (TrailBlazer, Envoy, Bravada) Trim Panel Replacement - Rear Quarter Upper (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the cargo shade/cover. 2. Remove the screw that retains the trim panel to the body. 3. Remove the cargo net retaining knobs. 4. Remove the bolt that retains the seat belt upper guide to the body. 5. Remove the rear upper quarter trim panel from the vehicle. Installation Procedure 1. Install the rear upper quarter trim panel to the vehicle. 2. Install the seat belt retractor to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the rear seat belt upper guide to the body. Tighten the rear seat belt upper guide shoulder bolt to 70 N.m (52 lb ft). 4. Install the screw that retains the rear upper quarter trim panel to the body. Tighten the rear upper quarter trim panel screw to 2 N.m (18 lb in). 5. Install the cargo net retaining knobs. Page 9415 Page 7140 4. Install the harness end bolts (2). 5. Install the fuse relay center cover (1) over the relay center bolts. Press downward to engage the tabs. 6. Install the junction block cover. Press downward to engage the tabs. Page 5430 Disclaimer Page 3050 Steps 20-22 A/C - Slow to Cool in Hot/Humid Conditions Fan Clutch: All Technical Service Bulletins A/C - Slow to Cool in Hot/Humid Conditions Bulletin No.: 04-01-38-019A Date: June 07, 2005 TECHNICAL Subject: Intermittent Slow to Cool HVAC Performance Concerns in High Ambient Temperatures and/or High Humidity Conditions After Start Up, Especially at Low Engine Speeds (Install New Engine Cooling Fan Clutch) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer Models 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005 Saab 9-7X Supercede: This bulletin is being revised to provide repair information for this customer concern. Please discard Corporate Bulletin Number 04-01-38-019 (Section 01 - HVAC). Condition Some customers may comment on slow to cool Air Conditioning (A/C) performance or high A/C outlet temperatures after start up or that the A/C system is not cooling sufficiently, especially in high ambient temperatures. This may be an intermittent condition and the performance of the Heating, Ventilation and Air Conditioning (HVAC) system may not meet customer expectations. Cause This condition may be caused by the response of the Electro-Viscous (EV) fan clutch and can be related to airflow across the condenser. This low A/C system performance can occur for longer periods of time if the vehicle is allowed to idle or is driven in low speed conditions. The response of the EV fan clutch will affect A/C system performance. As higher road speeds are attained, the increased airflow across the condenser will usually improve A/C system performance and the response of the EV fan clutch. This condition may be more evident after the vehicle has set for a period of time and can be difficult to duplicate. The condition may occur after the vehicle has set for as little as 10 minutes or as long as overnight. It is most prevalent intermittently during the first 15 minutes of operation. Correction Technicians are to replace the EV fan clutch with a new design part, P/N 15293048, on vehicles built before June 2005. Vehicles built in June 2005 may already have the updated EV fan clutch and it will not need to be replaced. For 2004 model year vehicles and older, update the Powertrain Control Module (PCM) with a software calibration that was developed to improve coolant temperature gauge readings. This new calibration will cause the PCM to command small amounts of additional fan engagement to better control engine coolant temperatures. Model year 2005 vehicles already have this calibration installed. Refer to Corporate Service Bulletin Number 04-06-02-005 for more information about this calibration. Proper diagnosis of any customer concern is essential. Refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure in SI to begin a diagnosis of any HVAC concerns. Refer to the Diagnostic Starting Point-Engine Cooling procedure in SI to begin a diagnosis of any engine cooling or engine cooling fan concerns. If an attempt is made to diagnose an HVAC system concern, all parameters must be measured. As an example, both the low and high side refrigerant pressure readings must be measured. If only the low side pressure readings were measured, it would appear that the A/C compressor is disengaging at a higher pressure than expected. If both the low and high side pressures were being measured, it would be noted that the A/C compressor is probably disengaging due to the maximum high side pressure cut out point being reached. This occurs to protect the HVAC system from damage. The updated PCM software calibration along with the updated EV fan clutch will improve this condition due to increased air flow across the condenser. The new EV fan clutch has an increased minimum operating fan speed and an improved response time. Additional engine cooling Page 1763 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 566 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 9645 Page 10421 Page 9356 Various symbols in order to describe different service operations. Page 12309 Sunroof Harness With Headliner Removed A/T - Water Or Coolant Contamination Information Transmission Cooler: All Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 12065 WA810K/48 - WA812K/88 Page 9383 Abbreviations And Meanings Part 17 Page 3750 Steps 14-15 Page 2207 Location View Paint - Chips Behind Front Wheels/Front of Rear Wheels Paint: All Technical Service Bulletins Paint - Chips Behind Front Wheels/Front of Rear Wheels Bulletin No.: 03-08-111-002G Date: December 21, 2007 TECHNICAL Subject: Paint Chipping Behind Front wheels/Front of Rear Wheels Damaged Lower Door/Cladding and Rocker Panels (Repaint Damaged Area Install Assist Step) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2008 Chevrolet TrailBlazer 2006-2007 Chevrolet TrailBlazer 55 2002-2006 GMC Envoy XL 2002-2008 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Attention: Implementation of this Service Bulletin requires case-by-case review and approval by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) PRIOR to the performance of any repairs. Supercede: This bulletin is being revised to add the 2008 model year for TrailBlazer Envoy and Saab 9-7X models and change the refinish materials reference. Please discard Corporate Bulletin Number 03-08-111-002F (Section 08 - Body and Accessories). Condition Some customers may comment that the paint is chipped just behind the front wheels as well as just in front of the rear wheels. Some customers may also comment about damage to the lower door/cladding and rocker panels. Cause The rocker and lower door areas may be damaged by road debris thrown up by the tires at highway speeds. Correction It may be necessary to perform the following repair in order to meet customer expectations and gain their product satisfaction. Follow the manufacturers specifications for repainting the lower door/cladding and rocker panel and refer to the 2008 GMWI5406 GM Globally Approved Refinish Materials information for the type of paint and refinish materials to use. The refinish materials information is now online at the GMGOODWRENCH WEB SITE*. Printed books have been discontinued. To access the site follow these steps: Go to www.gmgoodwrench.com. Click on For Body Shops & Services link at the bottom of the page. Click on GM Technical Repair Information. Click on Paint Shop tab. Select the applicable downloadable link of the GM Approved Refinish Materials Guide. *In Canada the 2008 GM Approved Refinish Materials information is also available on the GM infoNET under the Service and Body tab. For all of the above vehicles except TrailBlazer SS install the assist step. For the TrailBlazer SS install a Protector Kit P/N 15783524. Instructions are included in the kit. Page 2409 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 10170 Page 364 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 13670 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition contained in this bulletin are to be submitted by August 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle Page 10434 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 2335 ^ Always inspect and adjust the pressure when the tires are cold. ^ Vehicles that have different pressures for the front and the rear need to be adjusted after tire rotation. Improper tire inflation may result in any or all of the following conditions: ^ Premature tire wear ^ Harsh ride ^ Excessive road noise ^ Poor handling ^ Reduced fuel economy ^ Low Tire Pressure Monitor (TPM) Light ON ^ Low Tire Pressure Message on the Drivers Information Center (DIC) Disclaimer Page 2255 Application Table Part 1 Page 13131 Abbreviations And Meanings Part 3 Page 9800 Conversion - English/Metric Part 2 Page 8505 HVAC Control Module C1 Part 2 Page 12637 2. Install the seat switch to the seat bezel assembly. Verify that the retaining tabs are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Page 6167 Page 6897 Abbreviations And Meanings Part 12 Page 8518 1. Connect the HVAC control-auxiliary electrical connector. 2. Install the HVAC control-auxiliary in the console bottom first. 3. Push in at the top of the HVAC control-auxiliary in order to engage the HVAC control-auxiliary in the console/seat. Primary HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP accessory trim plate. 2. Remove the HVAC control module screws. 3. Depress the HVAC control module tabs (3) and remove the HVAC control module (2) from the IP (4). A/T, Exhaust - Rattling Noise From Under the Vehicle Fluid Line/Hose: All Technical Service Bulletins A/T, Exhaust - Rattling Noise From Under the Vehicle Bulletin No.: 04-07-30-002 Date: January 20, 2004 TECHNICAL Subject: Rattle Type Noise Coming From Under the Vehicle (Reposition Transmission Oil Cooler Lines) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on a rattle type noise coming from under the vehicle. Cause This condition may be caused by one of the transmission oil cooler lines contacting the exhaust catalytic converter. Correction Raise the vehicle and carefully reposition the transmission oil cooler line(s) to provide 10 mm (0.393 in) clearance between the exhaust catalytic converter and the line. Replace the transmission oil cooler line if any damage is present. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Engine, Right Front Park Brake Cable Replacement Parking Brake Cable: Service and Repair Park Brake Cable Replacement Park Brake Cable Replacement Removal Procedure Notice: Handling the parking brake cables during service requires extra care. Damage to the nylon coating reduces the corrosion protection. If the damage area passes through the nylon coating, increased parking brake effort could result. Avoid contacting the protective coating with sharp-edge tools or the sharp surfaces of the vehicle underbody. 1. Disable the park brake automatic adjuster. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the rear propeller shaft. 4. Remove the park brake cables from the parking brake equalizer. 5. Remove the park brake cables from the retainer. Important: When serving the left park brake cable, the fuel tank DOES NOT have to be removed. Service and Repair Power Trunk / Liftgate Lock Actuator: Service and Repair Lock Actuator Replacement - Lift Gate Removal Procedure 1. Remove the liftgate latch assembly from the liftgate. 2. Place the latch assembly on a clean, prepared surface. 3. Remove the 2 screws (2) that retain the lock actuator (1) to the latch assembly. 4. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. Installation Procedure 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. Important: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 3. Install the actuator to the top of the latch. Page 3659 Engine Oil Level And Temperature Sensor Page 624 Driver Door Module (DDM) - C2 Part 2 Diagrams Hood Ajar Switch (Export) Page 6349 1. Drain all the brake fluid from the caliper. 2. Pad the interior of the caliper with clean shop towels. Caution: Do not place your fingers In front of the piston in order to catch or protect the piston while applying compressed air. This could result In serious injury. Notice: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding. 3. Remove the piston from the caliper bore. 4. Remove the boot from the caliper bore. Do not scratch the housing bore. 5. Remove the piston seal from the caliper bore. Do not use a metal tool. Page 12118 Page 10541 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 1115 Seat Lumbar Motors And Position Sensors Assembly - Front Passenger Part 1 Page 7092 C201 Part 4 Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 5047 For vehicles repaired under warranty, use the table. Disclaimer Page 1760 Abbreviations And Meanings Part 24 Page 1466 Camshaft Position (CMP) Sensor Page 11156 Page 7280 Abbreviations And Meanings Part 16 Page 14027 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 8378 English Prevailing Torque Fastener Minimum Torque Development Part 1 Instruments - Erratic Speedometer Operation Engine Control Module: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 4689 Page 11469 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 7278 Abbreviations And Meanings Part 14 Page 9365 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 6216 Abbreviations And Meanings Part 15 Page 6463 Brake Master Cylinder: Service and Repair Master Cylinder Replacement MASTER CYLINDER REPLACEMENT Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. 1. Apply the parking brake and block the wheels. 2. Disconnect the brake pipes from the master cylinder. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. 3. Install the rubber plugs the brake pipe ends. 4. Remove the master cylinder nuts and bolts. Page 8211 Air Temperature Actuator-Left Page 12155 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 11244 * The sound deadening materials. * An approved anti-corrosion primer. * The sealers and refinish as necessary. 8. Install all of the related panels and components. Page 7172 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Technician Safety Information Positive: Technician Safety Information CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. - Follow each step of the jump starting procedure in order. - Treat both the booster and the discharged batteries carefully when using the jumper cables. Page 8127 Installation Procedure 1. Install the splash shield to the steering knuckle. Align the splash shield to the steering knuckle threaded holes. 2. Install the wheel hub and bearing to the steering knuckle. Align the threaded holes. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel hub and bearing to the steering knuckle mounting bolts. Tighten the wheel hub and bearing mounting bolts to 105 Nm (77 ft. lbs.). 4. Install the ABS sensor to the wheel hub and bearing. 5. Install the ABS sensor mounting bolt to the wheel hub and bearing. Tighten the ABS sensor to the wheel hub and bearing mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the brake rotor. 7. Install the tire and wheel. Page 13912 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 6949 Fuse Block - Rear C1 Part 2 Page 765 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs to correct the condition contained in this bulletin are to be submitted by August 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle Page 7220 Page 10959 1. Position the fascia to the vehicle, ensuring that the body side attachment tabs are fully seated. 2. Install the 4 push-pins that retain the bottom of the fascia to the headlamp panel assembly. 3. Install the push-pins (3) that retain the fascia to the fascia support rods (2). 4. Install the air defector. 5. Install the cornering lamps. 6. Install the fog lamps. 7. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the 2 bolts that retain the top of the fascia to the headlamp panel assembly. Tighten the bolts to 10 N.m (89 lb in). 9. Install the push-pin that retains the center of the top of the fascia to the headlamp panel assembly. 10. Install the grille. Page 7747 6. Remove the steering wheel control switch from the steering wheel. Installation Procedure 1. Position the steering wheel control switch to the steering wheel. 2. Connect the electrical connector to the steering wheel control switch. 3. Install the steering wheel control switch into the steering wheel, ensuring the retaining tabs are fully seated. 4. Install the shroud to the steering wheel. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the shroud retaining screws to the steering wheel. Tighten the screws to 2 Nm (18 inch lbs.). 6. Install the steering wheel. Page 5522 For vehicles repaired under warranty, use the table. Disclaimer Page 7742 1. Inspect the cylinder lines (1) for the following items: ^ Cracks ^ Dents ^ Damage to the threads 2. Replace the parts as needed. 3. Lubricate and install the O-rings seals (2) onto the cylinder lines (1). Important: You must install the smaller cylinder line into the valve housing (3) first. 4. Place the smaller cylinder line (2) into the valve housing (3). Important: Hold the smaller cylinder line (2) in place. Do not torque the cylinder line nut (1). 5. Place the other end of the cylinder line at the gear tube end (4). Finger tighten the cylinder line nut (1) on the smaller cylinder line. Important: You must install the larger cylinder line into the valve housing (3) first. Page 253 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Specifications Crankshaft: Specifications Crankshaft Main Journal Diameter 2.7567-2.7574 inch Main Journal Taper - Maximum 0.0002 inch Out Of Round - Maximum 0.0002 inch Cylinder Block Main Bearing Bore Diameter 3.0760-3.0766 inch Crankshaft Main Bearing Inside Diameter 2.7579-2.7592 inch Main Bearing Clearance 0.0004-0.0025 inch Crankshaft End Play 0.0044-0.0153 inch Page 10776 For vehicles repaired under warranty, use the table. Disclaimer Page 13986 Heated Glass Element: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS HVAC CONTROL MODULE Rear Defrost Switch: The scan tool displays On/Off. When the rear window defogger switch is depressed, the scan tool displays will momentarily display On. LIFTGATE MODULE (LGM) Rear Defog Requested: The scan tool displays Yes/No. When the rear window defogger switch is depressed, the HVAC control module sends a class 2 message to the LGM to enable the rear window defogger. The LGM enables the rear window defogger, which the scan tool displays as Yes. HVAC Control Module Liftgate Module (LGM) Liftgate Module (LGM) Page 4236 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 11045 Front Door Hinge: Service and Repair Hinge Replacement - Front Door - Door Side Hinge Replacement - Front Door - Door Side Removal Procedure The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all. 1. Remove all of the related panels and components. 2. Remove the sealer surrounding the hinge (1). 3. Scribe the location of the hinge (1). 4. Hand-sand the existing hinge (1) with 100 grit sandpaper to locate the 4 weld locations. Page 6968 Fuse Block - Underhood C1 Part 4 Page 4392 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. 2. Disconnect the negative battery terminal. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the Page 6687 Abbreviations And Meanings Part 9 Page 12010 WA379E/86 - WA382E/11 Specifications Generator Usage Page 13007 Abbreviations And Meanings Part 8 Page 4020 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 284 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4286 Abbreviations And Meanings Part 20 Page 13216 Page 8214 Defrost Actuator Page 8494 Lower Console (w/Automatic - HVAC System) (Body Type VIN 6) Page 11171 An initial supply of weatherstrips required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of February 6, 2006, and will be approximately 10% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Important: It is estimated that less than 10% of involved vehicles will require lock replacement. Please order parts accordingly. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to the recall condition are to be submitted to dealers by February 28, 2007. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Claim Information Page 3945 Registered And Non-Registered Trademarks Part 6 Page 12030 WA8554/40 - WA8555/41 Page 11664 33. Install the nut (1) securing the stowage jack carrier to the wheelhouse panel. 34. Install the right rear quarter lower trim panel. 35. Install the left rear quarter lower trim panel. 36. Install the left/right rear body side trim rear window garnish molding. 37. Install the left/right front body side window garnish molding. 38. Install the lift gate door sill plate. 39. Install the cargo tie-down loops. Tighten the cargo tie-down loop bolts to 35 N.m (26 lb ft). 40. Install the rear side door sill plates. 41. Install the second row seats. 42. Install the third row seats. 43. Install the luggage/cargo shade assembly, if equipped. 44. Install the cargo net, if equipped. A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: Customer Interest A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Page 11467 Cowl Moulding / Trim: By Symptom Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Page 9698 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 4307 Body Control Module (BCM) C3 Part 3 Powertrain Control Module (PCM) C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Powertrain Control Module (PCM) C1 Part 1 Page 1614 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch Connector, Wiring Harness Slde Page 9005 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the EFS connectors to both (2) EFS's. 3. Install the CPAs to both EFS connectors. 4. Install sensor bracket to bumper. 5. Install the grille. 6. Install the SIR fuse into the fuse block (1) located in the underhood fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 1. Remove the key from the ignition. Page 13516 Courtesy/Reading Lamp - RF Page 8749 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 2050 1. Install the inlet radiator hose clamps to the radiator hose (1). 2. Install the inlet radiator hose (1) to the radiator. 3. Reposition the inlet radiator hose clamp using J 38185. 4. Install the lower radiator support shield, if equipped. 5. Lower the vehicle. 6. Install the inlet radiator hose to the thermostat (1). 7. Reposition the inlet radiator hose using J 38185. 8. Fill the cooling system. Body VIN Code 6 Radiator Hose Replacement - Inlet (Body Vin Code 6 LL8 / GMT 370) Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the coolant. Page 537 Door Module: Locations Door Lock Switch, Window Switch, Driver Door Module (DDM) Page 6403 20. Wait approximately 30 seconds, and then inspect the new left front brake pipe and fittings for leaks. Any brake leaks identified must be repaired prior to completing this bleed procedure. 21. Install a proper size box-end wrench onto the left front wheel hydraulic circuit bleeder valve (screw) located on the caliper. 22. Install a transparent hose over the end of the bleeder valve. 23. Submerge the open end of the transparent hose into a transparent container partially filled with DOT-3 brake fluid from a clean, sealed brake fluid container. 24. Loosen the bleeder valve to purge the air from the left front wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, and then tighten the bleeder valve. 25. Close the J 29532, or equivalent, fluid tank valve, and then disconnect the J 29532, or equivalent, form the J 35589-A. 26. Remove the J 35589-A from the brake master cylinder reservoir. 27. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 28. Connect a Tech 2 to the vehicle's diagnostic link connector (DLC) and perform the automatic bleed procedure. 29. After completion of the automatic bleed procedure, slowly depress the brake fluid and verify that it feels firm. Release the pedal. 30. Verify that the fluid in the master cylinder reservoir is at the maximum-fill level. 31. Install the GM Recall Identification Label. Recall 05V198000: Flasher Module Replacement Turn Signal Flasher: All Technical Service Bulletins Recall 05V198000: Flasher Module Replacement MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2004 Chevrolet/Trailblazer 2003-2004 GMC/Envoy 2003-2004 Isuzu/Ascender 2003-2004 Oldsmobile/Bravada 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V198000 RECALL DATE: April 29, 2005 COMPONENT: Exterior Lighting: Turn Signal POTENTIAL NUMBER OF UNITS AFFECTED: 286478 SUMMARY: On certain trucks and sport utility vehicles, the driver wishing to signal a turn by moving the directional signal lever, (up or down) may cause the front marker/turn lights and rear turn lights to flash in a manner similar to hazard warning, rather than flashing on the desired side only. CONSEQUENCE: The driver may not be able to clearly signal their intentions to turn, change travel lanes, or potentially warn others of an impaired vehicle operating condition increasing the risk of a crash. REMEDY: Dealers will replace the suspect flasher modules with a new flasher module designed with sealed relays and more durable contact material inside of the relays. The recall is expected to begin during August 2005. owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727, Buick at 1-866-608-8080, and Oldsmobile at 1-800-630-6537. NOTES: GM recall No. 05044. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Page 555 Door Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 3958 Door Control Module Diagram 3 Page 10017 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Locations Park Neutral Position (PNP) Switch Page 5322 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Page 12294 4. Install the overhead console to the roof. Page 11781 Page 12999 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 432 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Emissions - DTC P0440/P0455/P0442 (EVAP) Diagnostics Fuel Filler Neck: All Technical Service Bulletins Emissions - DTC P0440/P0455/P0442 (EVAP) Diagnostics Bulletin No.: 05-06-04-014A Date: March 21, 2005 INFORMATION Subject: Diagnostic Aids for Diagnostic Trouble Codes P0440, P0455 and/or P0442 - Evaporative Emission (EVAP) System Leak Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada with 83 Liter (22 Gallon) or 96 Liter (25 Gallon) Fuel Tanks Supercede: This bulletin is being revised to remove the 2005 model year. Please discard Corporate Bulletin Number 05-06-04-014 (Section 06 - Engine/Propulsion System). This bulletin is being published to aid technicians in the diagnosis of DTCs P0440, P0455 and/or P0442. It is possible that a fracture as small as 0.508 mm (0.020 in) may be found in the fuel tank filler neck, causing a DTC P0440, P0455 and/or P0442 to set. Due to the location above the liquid fuel level, this small fracture will not cause a visible fluid leak. The technician should pay particular attention to the fuel tank filler neck area while performing the smoke test outlined in SI. Refer to the appropriate diagnostic information for P0440, P0455 and/or P0442 in SI. When performing the smoke test outlined in SI, it may be necessary for the technician to manipulate the fuel tank filler neck in order to see smoke escaping from this minute fracture. Disclaimer Page 1676 For vehicles repaired under warranty, use the table. Disclaimer Page 8397 Abbreviations And Meanings Part 17 Page 11184 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 3 fasteners that retain the latch to the door. Tighten the fasteners to 10.0 N.m (22 lb in). 5. Install the outside handle lock rod to the outside handle. 6. Install the inside door handle lock rod to the latch. 7. Install the water deflector. 8. Install the door trim panel. Page 9656 Locations Engine, Left Side Page 9635 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 886 Registered And Non-Registered Trademarks Part 5 Page 12365 Memory Seat Module - Passenger C4 Part 1 Page 13156 Registered And Non-Registered Trademarks Part 2 Page 8384 Abbreviations And Meanings Part 4 Page 12031 WA8555/41 - WA8555/41 Page 4622 Steps 4-5 Page 5766 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 1226 Air Temperature Sensor Assembly-Inside Page 11672 16. If the vehicle is equipped with a sunroof, seat the 6 interlocking strips. 17. Reach underneath the carpet and remove the headliner harness electrical connector (1) from the IP wire harness. 18. Install the center pillar headliner harness electrical connector to the bussed electrical center, and the block base to the floor panel. 19. Install the headliner harness retaining clips (2) to the rocker panel and the floor panel. 20. Install the headliner harness to the left center pillar. 21. Install the following headliner harness clips to the center pillar: * The center pillar harness clips (1) * The center pillar harness clips (3) * The center pillar harness clips (4) Notice: Refer to Fastener Notice in Service Precautions. 22. Install the ground terminals and the ground bolt (2) to the center pillar. Tighten the bolt to 10 N.m (88 lb in). 23. If equipped with OnStar(R) perform the following procedure: 1. Install the navigation antenna cable to the right center pillar. 2. Install the navigation antenna cable to the right side door sill attachments. 3. Install the navigation antenna cable to the communication interface module. 24. Install the sunshades to the headliner. 25. If equipped, install the front and rear overhead console. Refer to Overhead Console Replacement - Front, or to Overhead Console Replacement - Page 9418 Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 11617 Console: Service and Repair Bracket Replacement - Console Floor Bracket Replacement - Console Floor Removal Procedure 1. Block the wheels to prevent the vehicle from moving. 2. Remove the floor shift control knob. 3. Remove the center console. Console Replacement 4. Disconnect the automatic transmission range selector cable. 5. Disconnect the electrical connector from the automatic transmission shift interlock solenoid. 6. Disconnect the electrical connector from the park brake. 7. Remove the console bracket from the vehicle, by removing the retaining nuts (1) from the center instrument panel (IP) bracket. 8. Remove the forward retaining screw, if equipped. 9. Remove the remaining fasteners from the console bracket. 10. Remove the console bracket from the vehicle. 11. Remove the floor shift control. Installation Procedure 1. Install the floor shift control. 2. Install the console bracket to the vehicle. 3. Loosely install all the fasteners that retain the console bracket to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the retaining nuts (1) to the center IP bracket. Tighten nuts to 10 N.m (88 lb in). 5. Install the remaining fasteners that retain the console bracket to the vehicle. Tighten the nuts to 25 N.m (18 lb ft). 6. Connect the electrical connector to the park brake. 7. Connect the electrical connector to the automatic transmission shift interlock solenoid. 8. Connect the automatic transmission range selector cable. 9. Install the center console. Console Replacement 10. Install the floor shift control knob. 11. Remove the wheel blocks from the vehicle. Console Replacement Page 7808 The steering wheel puller legs currently recommended in the Service Manual for use with steering wheel puller J 1859-A are incorrect and will not work on these vehicles. The correct steering wheel puller legs that should be used with steering wheel puller J 1859-A are J 36541-A or J 42578. The Steering Wheel Replacement procedure has been updated with the correct steering wheel puller tool usage. Refer to the table for SI Document ID numbers. Disclaimer Page 330 Page 2916 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 12039 WA9260/74 - WA9260/74 Page 13228 Page 2765 Page 9901 Page 4059 Chassis Harness, Fuel Tank Page 7909 8. Loosen the air spring level sensor to the frame mounting bolts. Important: If not equipped, use a new anti-rotation bolt (P/N 11569736). 9. Loosely install the sensor mounting bolts with the anti-rotation bolt in the right hand mounting hole. Notice: Refer to Fastener Notice in the Preface section. Important: Do not remove the air spring level sensor locating pin until the air spring level sensor has been properly mounted and aligned. 10. Install the air spring level locating pin. A 4 mm drill bit or equivalent can be substituted. Tighten 1. While holding the body of the sensor, tighten the anti-rotation bolt first. 2. Tighten the air spring level sensor frame mounting bolts to 8 Nm (71 lb in). Page 11551 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 11913 4. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the C clip to the groove in the lock cylinder. 3. Install the lock rod to the lock cylinder. 4. Install the rear wiper motor. Page 7171 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 2052 4. Install the lower radiator support shield, if equipped. 5. Lower the vehicle. 6. Install the inlet radiator hose to the thermostat (1). 7. Reposition the inlet radiator hose using J 38185. 8. Fill the cooling system. Page 7506 C900 Page 7628 Page 608 Abbreviations And Meanings Part 20 Page 4101 5. Tape over the entire cable. Use a winding motion when you apply the tape. Paint - Chips Behind Front Wheels/Front of Rear Wheels Paint: Customer Interest Paint - Chips Behind Front Wheels/Front of Rear Wheels Bulletin No.: 03-08-111-002G Date: December 21, 2007 TECHNICAL Subject: Paint Chipping Behind Front wheels/Front of Rear Wheels Damaged Lower Door/Cladding and Rocker Panels (Repaint Damaged Area Install Assist Step) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2008 Chevrolet TrailBlazer 2006-2007 Chevrolet TrailBlazer 55 2002-2006 GMC Envoy XL 2002-2008 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Attention: Implementation of this Service Bulletin requires case-by-case review and approval by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) PRIOR to the performance of any repairs. Supercede: This bulletin is being revised to add the 2008 model year for TrailBlazer Envoy and Saab 9-7X models and change the refinish materials reference. Please discard Corporate Bulletin Number 03-08-111-002F (Section 08 - Body and Accessories). Condition Some customers may comment that the paint is chipped just behind the front wheels as well as just in front of the rear wheels. Some customers may also comment about damage to the lower door/cladding and rocker panels. Cause The rocker and lower door areas may be damaged by road debris thrown up by the tires at highway speeds. Correction It may be necessary to perform the following repair in order to meet customer expectations and gain their product satisfaction. Follow the manufacturers specifications for repainting the lower door/cladding and rocker panel and refer to the 2008 GMWI5406 GM Globally Approved Refinish Materials information for the type of paint and refinish materials to use. The refinish materials information is now online at the GMGOODWRENCH WEB SITE*. Printed books have been discontinued. To access the site follow these steps: Go to www.gmgoodwrench.com. Click on For Body Shops & Services link at the bottom of the page. Click on GM Technical Repair Information. Click on Paint Shop tab. Select the applicable downloadable link of the GM Approved Refinish Materials Guide. *In Canada the 2008 GM Approved Refinish Materials information is also available on the GM infoNET under the Service and Body tab. For all of the above vehicles except TrailBlazer SS install the assist step. For the TrailBlazer SS install a Protector Kit P/N 15783524. Instructions are included in the kit. Page 11198 Install the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws that retain the lock striker to the door opening. Tighten the lock striker screws only until the screw heads are flush to the lock striker plate, but still allowing the striker to move. Using a large flat-bladed tool, rock the striker up and down in order to loosen the striker backing plate from the body. Do not slam the door. Close the door while holding the outside handle in the open position in order to align the lock striker. If necessary, adjust the striker position in order to allow the door to close with minimum effort. Open the door. Finish tightening the lock striker screws. Tighten Tighten the lock striker screws to 25 N.m (18 lb ft). Verify proper door operation. Warranty Information (excluding Saab U.S Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S Models) For 2005 and 2006 vehicles - Adjustment of the striker plate is only covered for 1 year or 16,000 miles, whichever occurs first. Page 11471 Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). Page 9658 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 3165 40.6. Install the ring terminal (orange wire) to the underhood fuse block stud (1). 40.7. Locate circuit no. 241 or 441 (ignition 3 brown wire) (PIN B11 or C11) in the existing underhood fuse block harness (1) of C2 (2) and splice bare wire to it using a splice clip. Wrap with electrical tape. 40.8. Locate connector C105 (3), located on the left side inner fender. Separate the connector halves. On the female side of the connector, remove the terminal from cavity F (gray/black wire) and tape back. 40.9. Install the terminal end on the pump wiring harness into cavity F of connector C105. 41. Install the evaporator tube and nut to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 42. Install the coolant recovery reservoir with the accumulator attached. 43. Install the nut and bolt securing the coolant recovery reservoir. 44. Install the coolant hoses to the coolant recovery reservoir. 45. Install the nut retaining the accumulator to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 46. Install the compressor suction hose assembly to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). Page 11797 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 11616 12. Stake the other end of the retainer: 12.1. Remove the punch, part of J 41340. 12.2. Rotate the punch, part of J 41340, 180 degrees. 12.3. Hold the punch, part of J 41340, squarely against the end of the punch slot on J 41340. 12.4. Stake the metal over the other end of the retainer. 13. Loosen the holding screw. 14. Remove the cylinder from the J 41340. 15. Inspect that the retainer is properly staked. Restake as needed. 16. Lubricate the cylinder retainer slot. 17. Insert the following parts into the cylinder retainer slot: - The retainer spring (2) - The retainer (3) 18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed: - The detent pins (1) - The cylinder retainer (3) IMPORTANT:Use a paste type grease, not a spray, for the above step. SIDE DOOR LOCK CYLINDER CODING The side door lock cylinder has five snap-in tumblers. The number 1-5 positions (beginning closest to the cylinder head) is a brass retainer tumbler. The 6-10 positions are standard tumbler positions. Therefore, only the 6-10 positions are required. Page 2584 NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 6. While still holding the flywheel, install the balancer washer and a new bolt. Tighten the crankshaft balancer bolt to 150 Nm (110 ft. lbs.). Use the J 45059 in order to tighten the balancer bolt an additional 180°. 7. Remove the torque converter holding tool. 8. Install the torque converter access plug into the oil pan. 9. Lower the vehicle. 10. Install the drive belt. 11. Install the radiator. Page 3451 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 10149 A/C - Poor Rear Heater Performance Auxiliary Water Pump: All Technical Service Bulletins A/C - Poor Rear Heater Performance Bulletin No.: 05-01-37-002A Date: November 01, 2005 TECHNICAL Subject: Poor Rear Heat Performance (Install Auxiliary Heater Pump) Models: 2003-2005 Chevrolet TrailBlazer EXT 2003-2005 GMC Envoy XL Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 05-01-37-002 (Section 01 - HVAC). Important: Implementation of this Service Bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on poor 2nd and/or 3rd row seating heater performance when the vehicle is at idle. Cause This condition may be due to lack of coolant circulation to the rear heater core. Correction Install auxiliary heater pump package, P/N 89024885 (L6 Engine RPO LL8) or P/N 89024886 (V8 Engine RPO LM4 or LH6). This pump will improve coolant flow to the rear heater core. Use the procedure listed below. 1. Recover the A/C refrigerant. 2. Drain the cooling system. 3. Disconnect the negative battery cable. 4. Remove the fender rear upper brace. 5. Remove the air cleaner cover. 6. Remove the air cleaner filter element and air outlet duct. 7. Remove the air inlet duct from the lower air cleaner housing/washer solvent tank assembly. 8. Disconnect the washer solvent tank electrical and remove wiring harness from the retaining clips. 9. Disconnect the washer pump hoses and plug the pump outlet ports to prevent loss of washer solvent. 10. Remove the two air cleaner housing/washer tank assembly retaining nuts from the mounting studs. 11. Lift the lower air cleaner housing/washer tank assembly off of the studs and remove the assembly. 12. On the A/C accumulator, disconnect the electrical connector from the low pressure switch. 13. Remove the compressor suction hose assembly from the accumulator. 14. Remove the nut retaining the accumulator to the evaporator. 15. Remove the coolant hoses from the coolant recovery reservoir. Page 1552 2. Position the sensor assembly horizontally above the front bumper. 3. Connect the sensor (2) electrical connector. 4. Install the connector-position assurance (CPA) to the sensor electrical connector. 5. Install the retaining bolts and protective cover (1) to the sensor. 6. Position the sensor assembly horizontally to the frame (1). 7. Point the arrow on the sensor toward the front of the vehicle. 8. Install the 2 bolts (1) retaining the discriminating sensor assembly to the frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 8 N.m (71 lb in). Page 9154 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 2386 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 2172 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the grille. 6. Remove sensor bracket from bumper. 7. Remove the Connector Position Assurance (CPA) from both (2) electronic frontal sensor (EFS) connectors. IMPORTANT: This vehicle is equipped with two inflatable restraint electronic frontal sensors (EFS). When performing this procedure be sure to include both EFS's. 8. Disconnect both EFS connectors. Zone 2 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 5177 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Page 4084 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 3179 40.5. Route the other end of the harness along the rear of the engine compartment to the left side and secure to the cross bar and dash panel with tie straps. Page 7111 C312 Part 1 Recall - Flasher Relay Module Replacement Technical Service Bulletin # 05044 Date: 050728 Recall - Flasher Relay Module Replacement Bulletin No.: 05044 Date: July 28, 2005 SAFETY Subject: 05010 - INTERMITTENT INCORRECT TURN SIGNAL OPERATION Models: 2004 BUICK RAINIER 2003-2004 CHEVROLET TRAILBLAZER, TRAILBLAZER EXT 2003-2004 GMC ENVOY, ENVOY XL 2004 GMC ENVOY XUV 2003-2004 OLDSMOBILE BRAVADA Condition General Motors has decided that a detect, which relates to motor vehicle safety, exists in certain 2004 Buick Rainier and GMC Envoy XUV; 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles. Some of these vehicles have an intermittent condition in which the turn signals may not operate as designed. Material build up on the flasher relay may cause the turn signals to flash on both sides of the vehicle when activated similar to hazard warning flashers, or they may illuminate and remain illuminated instead of flashing. The instrument panel would indicate the incorrect operation if this were to occur. Incorrect operation of the turn signal indicator could fail to warn others of the driver's intentions and could lead to a vehicle crash. Correction Dealers are to replace the flasher relay module. Vehicles Involved Page 7363 Fuse Block - Underhood C7 Page 4823 Ignition Coil 3 Diagrams Windshield Wiper/Washer Switch (Turn Signal/Multifunction Switch C3) Page 9848 Steps 4-11 Page 8305 32. Install the new hose (1), # 1005 (L6 engine) or# 1006 (V8 engine) onto the coolant bypass valve at the location the above hose was removed. The other end of this hose will be installed on the auxiliary heater pump outlet port. Page 6694 Abbreviations And Meanings Part 16 Diagrams Mirror Switch, Driver Door Module (DDM) - C5 Description and Operation Clearance Lamp: Description and Operation PARK, TAIL, MARKER, LICENSE, AND CLEARANCE LAMPS The park, tail, marker, license, and clearance (Y92 only) lamps are turned on when the headlamp switch is placed in the PARK or ON position or anytime the headlights are requested. The I/P BATT fuse in the engine wiring harness junction block supplies battery positive voltage to both the park lamp relay switch contacts and the park lamp coil circuit. The body control module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the park lamps are turned on, the BCM energizes the park lamp relay. Current flow is from the park lamp relay to the individual park lamp circuit fuses and to their respective park, tail, marker, and license lamps. The front park and marker lamps are grounded at G107 and G103. The tail lamps are grounded at G401 and G402. The license lamps are grounded at G401. When equipped with the Y92 roof rack option, the clearance lamps are grounded at G302. If the driver places the headlight switch in the ON position after the ignition switch has been turned OFF, the park, tail, marker, license, and clearance lamps will remain on until turned off or the battery runs dead. The T PARK fuse in the rear fuse-relay block supplies battery positive voltage to a separate park lamp circuit connected to the trailer wiring harness. Page 11345 Power Trunk / Liftgate Control Module: Service and Repair LIFT GATE CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the liftgate window garnish molding. 2. Remove the liftgate trim panel. 3. Disconnect the electrical connectors (3) from the module as necessary. 4. Remove the bolts that retain the module to the liftgate. 5. Remove the module from the liftgate. INSTALLATION PROCEDURE 1. Install the module to the liftgate. 2. Install the bolts that retain the module to the liftgate. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Connect the electrical connectors (3) as necessary. 4. Install the liftgate trim panel. 5. Install the liftgate window garnish molding. 6. Reprogram the liftgate control module. Refer to Lift Gate Control Module Programming. Specifications Idle Speed: Specifications Engine Speed ...................................................................................................................................... .......................................................... 500 - 700 RPM Desired Idle Speed .............................................................................................................................. ........................................................ PCM Controlled Page 13883 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 9986 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 12283 Sun Shade: Technical Service Bulletins Body - Moonroof Sunshade Damage Prevention File In Section: 08 - Body and Accessories Bulletin No.: 02-08-110-005 Date: October, 2002 INFORMATION Subject: Avoiding Sunshade Damage During Removal And Installation Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Sunshades are being replaced in the field when not necessary because they are being damaged during the removal and installation process. Many sunshades are being reinstalled improperly during repairs to the overhead system causing the sunshades to be loose or fall out. The Sunshade Replacement procedure in SI (Document ID # 740348) has been revised to help reduce the number of cases of damage to the sunshades during removal and installation. Do not pry or use excessive force to remove the sunshades as this may damage the roof sheet metal at the sunshade attaching point. If necessary, straighten the roof sheet metal before reinstalling the sunshade. If the sheet metal is bent, it will result in a sunshade that is loose or it may fall out Warranty Information DISCLAIMER Page 2242 Fuse Block - Underhood C4 Part 1 Page 3827 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6795 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 11853 Mirror Connector, Driver Door Module (DDM) - C3 Part 2 Service and Repair Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 11033 4. Drill a 13 mm (1/2 in.) hole at each pilot hole location (2). 5. Clean and prepare all bare-metal surfaces. IMPORTANT: Prior to refinishing, refer to the publication GM4901MD-01 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an anti-corrosion primer. 7. Pass the feed wire (1) through the hinge (2), body pillar (3) and backing plate (4) as shown. 8. Crimp the feed wire (1) behind the backing plate. 9. Pull the feed wire (1) while guiding the backing plate (2) into the inner structure. Page 7480 C305 Part 2 Page 10117 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 7479 C305 Part 1 Page 9197 Registered And Non-Registered Trademarks Part 4 Page 13014 Abbreviations And Meanings Part 15 Page 1127 Seat Adjuster Switch - Passenger (w/o Heat) Part 1 Page 10181 Locations Electronic Components Page 13954 Abbreviations And Meanings Part 24 Page 11654 12. Stake the other end of the retainer: 12.1. Remove the punch, part of J 41340. 12.2. Rotate the punch, part of J 41340, 180 degrees. 12.3. Hold the punch, part of J 41340, squarely against the end of the punch slot on J 41340. 12.4. Stake the metal over the other end of the retainer. 13. Loosen the holding screw. 14. Remove the cylinder from the J 41340. 15. Inspect that the retainer is properly staked. Restake as needed. 16. Lubricate the cylinder retainer slot. 17. Insert the following parts into the cylinder retainer slot: - The retainer spring (2) - The retainer (3) 18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed: - The detent pins (1) - The cylinder retainer (3) IMPORTANT:Use a paste type grease, not a spray, for the above step. SIDE DOOR LOCK CYLINDER CODING The side door lock cylinder has five snap-in tumblers. The number 1-5 positions (beginning closest to the cylinder head) is a brass retainer tumbler. The 6-10 positions are standard tumbler positions. Therefore, only the 6-10 positions are required. Page 150 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 9565 Labor Time Information Page 7430 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 13932 Abbreviations And Meanings Part 2 Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Page 4444 Exhaust Pipe Page 7323 Location View Page 6887 Abbreviations And Meanings Part 2 Locations Passenger Seat Lumbar Actuators, Driver Seat Similar Locations Park Neutral Position (PNP) Switch Page 635 Door Control Module Diagram 2 Page 10738 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5323 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 9017 Child Seat Tether Attachment: Service and Repair Rear No. 1 (TrailBlazer EXT, Envoy XL) REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the trim panel from the seat cushion. 3. Remove the bolt (1) securing the child tether anchor (2) to the seat cushion frame. 4. Remove the child tether anchor. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the child tether anchor (2) to the seat cushion frame with the bolt (1). Tighten Tighten the child restraint tether anchor bolt to 35 N.m (26 lb ft). 2. Install the trim panel to the seat cushion. 3. Install the seat in the vehicle. Page 5136 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Page 5843 3. Install the pinion yoke. Align the marks made during removal. Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut. 6. Install the J8614-01 onto the pinion yoke as shown. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 7. Tighten the pinion nut while holding the J8614-01. Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. A/C - Intermittently Inoperative/Blows Warm Air Low Pressure Sensor / Switch: All Technical Service Bulletins A/C - Intermittently Inoperative/Blows Warm Air Bulletin No.: 03-01-39-007 Date: May 29, 2003 TECHNICAL Subject: Air Conditioning (A/C) Inoperative/Intermittent, A/C Blows Warm Air (Replace A/C Low Pressure Cycling Switch) Models: 2003 Cadillac Escalade, Escalade EXT, Escalade ESV 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2003 GMC Envoy, Envoy XL 2003 GMC Sierra, Yukon, Yukon XL 2002-2003 Oldsmobile Bravada 2003 HUMMER H2 Condition Some customers may comment that the A/C system is intermittently inoperative or blows warm air. Cause An intermittent inoperative (open) A/C low pressure cycling switch may be the cause. This is an intermittent condition and temperatures may play a critical role if the vehicle is in the failed mode or operating as designed. Correction Follow the diagnosis and service procedure below to correct this condition. 1. Park the vehicle inside or in the shade. 2. Open the windows in order to ventilate the interior of the vehicle. 3. If the A/C system was operating, allow the A/C system to equalize. 4. Turn OFF the ignition. 5. Open the hood and install fender covers. Caution: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Note: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and 0-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment Page 13961 Registered And Non-Registered Trademarks Part 5 Page 7783 Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement - Lower Intermediate Steering Shaft Replacement - Lower Tools Required ^ J42640 Steering Column Lock Pin Removal Procedure Notice: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 1. Turn the steering wheel so that the front wheels are pointing straight ahead. 2. Turn the ignition switch to the lock position and remove the key. 3. Lock the steering column through the access hole in the lower steering column trim cover using J42640. 4. Disconnect the upper intermediate shaft boot from the lower intermediate shaft boot to gain access to the upper intermediate shaft to lower intermediate pinch bolt. 5. Remove the lower intermediate shaft to upper intermediate shaft pinch bolt. 6. Disconnect the lower intermediate shaft from the upper intermediate shaft. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 9188 Abbreviations And Meanings Part 21 Page 12557 Abbreviations And Meanings Part 25 Page 5019 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Page 2236 Fuse Block - Underhood C2 Part 3 CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. The scan tool instructs you to perform the following items: - Accelerate to wide open throttle (WOT). - Release the throttle when fuel cut-off occurs. - Observe the fuel cut-off for the engine that you are performing the learn procedure on. - The engine should not accelerate beyond calibrated RPM value. - Release the throttle immediately if value is exceeded. - Block the drive wheels. - Set the parking brake. - DO NOT apply the brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn the A/C OFF. - The vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. With the scan tool, enable the crankshaft position system variation learn procedure. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release the throttle when the fuel cut-off occurs. 8. The scan tool displays Learn Status-Learned this ignition: - If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. - If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. - If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The crankshaft position system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P1336 sets: Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - Crankshaft position sensor replacement - Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 2897 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 13308 Door Switch: Diagrams Miniwedge (Door Jamb Switch) - LF Page 13033 Cigar Lighter Page 10152 Body - Front/Rear Side Door Glass is Scratched Window Seal: Customer Interest Body - Front/Rear Side Door Glass is Scratched Front or Rear Side Door Glass Scratched (Adjust Hem Flange) # 04-08-64-012C - (May 26, 2005) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada This bulletin is being revised to correct the model designations for the last four parts listed in the Parts Information table. Please discard Corporate Bulletin Number 04-08-64-012B (Section 08 -Body and Accessories). Condition Some customers may comment that the front or rear door glass has some vertical scratches on the outside of the door glass. Cause The inner and outer belt moldings may be too tight, causing dirt to get impregnated into the outer belt molding and causing scratches. Correction 1. Remove the Door Trim Panel-Side Front Door. Remove the outer belt molding. 2. Take a measurement between the inner and outer hem flange at the top of the door. Refer to the illustration above. If that measurement is 27 mm (1.06 in) or lower, proceed to step 3. 3. Close the door. 4. Wearing gloves, pull on the outer door skin to achieve a measurement of 28 mm (1.10 in) minimum to 31 mm (1.22 in) maximum. If the measurement cannot be achieved by pulling, use a pair of Vise Grip (Sheet Metal) pliers and bend the outer panel to get your measurement. 5. Install a new reveal molding. 6. Install a new door glass. Page 1551 5. Loosen the bolts (1) retaining the sensor to the frame. 6. Remove the sensor assembly from the frame (1). 7. Position the sensor assembly above the front bumper. 8. Remove the retaining bolts and protective cover (1) from the sensor. 9. Remove the connector-position assurance (CPA) from the sensor electrical connector. 10. Disconnect the sensor (2) electrical connector. 11. Remove the sensor from the vehicle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Page 10254 Amplifier: Description and Operation AUDIO AMPLIFIER The audio amplifier is standard on some vehicle lines but is optional on most. The radio supplies low level audio signals to the audio amplifier in order to boost the signal sent to the speakers. The class 2 signal circuit allows the radio to recognize that an amplifier is present. Once the radio detects an audio amplifier, it will output low level audio signals. The audio amplifier is turned on when it receives a message via the class 2 serial data circuit indicating that the radio is on. Page 13707 Turn Signal/Mutifunction Switch C2 Page 6962 Fuse Block - Rear C4 Part 1 Page 6672 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 11091 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the weatherstrip side retainer. Tighten the screws to the weatherstrip side retainer to 2 N.m (18 lb in). 3. Install the push pin retainers (2) to the front door sealing weatherstrip located at the base of the pillar. 4. Close the door. Page 28 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 9754 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (88 lb in). 6. Install the two rear overhead console carrier screws (1). Tighten Tighten the screws to 1.2 N.m (10 lb in). 7. Install the video display assembly. 8. Verify the video display for proper operation. 9. Close the video display screen. 10. Install the bolt cover bezel. Page 9651 Page 7144 6. Connect the mobile telephone harness connector (1) to the junction block. 7. Connect the instrument panel harness connector (1) to the block base. 8. Install the junction block to the block base. Ensure that the retaining tabs are fully seated. Page 7227 Communication Interface Module Replacement 1 Global Positioning System Module: Service and Repair Communication Interface Module Replacement 1 COMMUNICATION INTERFACE MODULE REPLACEMENT (TRAILBLAZER, ENVOY, BRAVADA) REMOVAL PROCEDURE 1. Position the right rear seat bottom to a cargo position. IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification and the 11-digit electronic serial number, are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 2. Remove the protective cover from the vehicle communication interface module (VCIM). 3. Remove the module from the upper bracket by releasing the retaining tab. Page 13142 Abbreviations And Meanings Part 14 Page 845 Various symbols in order to describe different service operations. Garage Door Opener Replacement Garage Door Opener Transmitter: Service and Repair Garage Door Opener Replacement GARAGE DOOR OPENER REPLACEMENT REMOVAL PROCEDURE 1. Remove the overhead console. 2. Disconnect the electrical connector from the garage door opener (3). 3. Remove the 3 retaining screws from the garage door opener. 4. Remove the garage door opener from the overhead console. 5. Remove the button assembly from the overhead console. INSTALLATION PROCEDURE 1. Install the button assembly to the overhead console. 2. Install the garage door opener to the overhead console. Fully recess the light indicator into the opening (1). Page 13162 Driver/Vehicle Information Display: Electrical Diagrams Driver Information Diagram Page 7116 C315 Part 2 Page 3178 40.1. Install the ring terminal (black wire) to ground G103 (1), located on the right side inner tender. 40.2. Route the pump wiring harness along the existing right side forward lamp harness. 40.3. Connect the electrical connectors to the coolant bypass valve (1) and auxiliary heater pump (2). 40.4. Position the relays onto the inner wheelhouse panel near the rear of the engine compartment. Page 11596 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 9912 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 3926 Abbreviations And Meanings Part 13 Page 13429 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Page 594 Abbreviations And Meanings Part 6 Page 11962 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 8578 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 11889 1. Install the rubber bumper (1) to the latch. 2. Rotate the actuator toward the latch in order to fully engage the rubber bumper into the latch. 3. Install the actuator to the top of the latch. IMPORTANT: Ensure that the first tooth of the gear on the actuator and the first tooth of the gear on the latch align and interlock properly. 4. Install the 2 screws that retain the actuator (1) to the lock. NOTE: Refer to Fastener Notice in Service Precautions. Page 12025 WA810K/48 - WA812K/88 Page 5877 Installation Procedure 1. Install the splash shield to the steering knuckle. Align the splash shield to the steering knuckle threaded holes. 2. Install the wheel hub and bearing to the steering knuckle. Align the threaded holes. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel hub and bearing to the steering knuckle mounting bolts. Tighten the wheel hub and bearing mounting bolts to 105 Nm (77 ft. lbs.). 4. Install the ABS sensor to the wheel hub and bearing. 5. Install the ABS sensor mounting bolt to the wheel hub and bearing. Tighten the ABS sensor to the wheel hub and bearing mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the brake rotor. 7. Install the tire and wheel. Page 10506 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 9775 Garage Door Opener Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 7356 Fuse Block - Underhood C3 Part 2 Page 9983 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 11465 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 2760 Page 10139 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 7796 For vehicles repaired under warranty, use the table. Disclaimer Page 4612 Fuel Injector: Description and Operation Fuel Injectors The Multec 2 fuel injector assembly is a solenoid device controlled by the control module that meters pressurized fuel to a single engine cylinder. The control module energizes the high-impedance, 12 ohms, injector solenoid (2) to open a normally closed ball valve (3). This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has four machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. Page 1323 Combination Switch: Diagrams Turn Signal /Mutifuction Switch C1 Page 13163 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION DRIVER INFORMATION CENTER (DIC) The driver information center (DIC) consists of a single line 22 character vacuum fluorescent (VF) display placed in the lower center area of the instrument panel cluster (IPC). The DIC will display vehicle information, configuration, and warning parameters to the driver. The display parameters are cycled, changed, and acknowledged using four (4) DIC buttons. Trip Information Button representation icon appears as a road to the horizon. - Fuel Information Button representation icon appears as a gasoline pump. - Personalization Button representation icon appears as a human next to vehicle. - Select Button representation icon appears as an arrow. DIC DISPLAYS The DIC parameters are displayed by order of priority as follows (from highest to lowest) : Service Diagnostics - Driver Identifier - Feature Programming - Driver Warnings - Vehicle Information VEHICLE INFORMATION Vehicle information provides feedback to the driver on vehicle performance, mileage, maintenance, or related information. Vehicle information can only be displayed with the ignition switch in the RUN position. When the English/Metric status changes, any applicable vehicle information data values will also change. DIC TRIP INFORMATION / RESET CAPABILITIES The available DIC Trip Information and reset capabilities are as follows: Odometer - Cannot be reset - Trip Odometer A - Can be reset - Trip Odometer B - Can be reset - Timer - Can be reset TRIP RESET STEM The trip reset stem on the IPC operates in the following manner with the ignition switch in the RUN position: 1. Each time the reset stem or SWC Select button is pushed the display will cycle to the next trip parameter. The trip parameters are as follows: - Odometer - Trip A odometer - Trip B odometer 2. Holding the reset stem for greater than 3 seconds or depressing the SWC Select button while either Trip A or Trip B odometer is displayed will reset the displayed trip odometer to 0.0 upon release of the stem. The trip odometer will remain displayed after being reset. 3. If a trip odometer parameter is being displayed, pressing the DIC Trip Information button will display the next trip odometer parameter. 4. If the next Trip Information parameter to be displayed is Timer or blank, pressing the reset stem will return the display to the Odometer. ODOMETER The odometer is capable of displaying values from 0 to 999,999 MI or KM. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip reset stem. The odometer will remain displayed for 5 seconds. TRIP ODOMETERS The DIC can display Trip A or Trip B odometers. The trip odometers are capable of displaying values from 0 to 9999.9 MI or KM. When the maximum value is reached, the trip odometer will roll over to 0.0. TIMER The Timer is displayed as XX (hours) : XX (minutes) : XX (seconds). Page 7121 C500 Part 2 OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 7777 12. Disconnect the lower intermediate shaft boot from the power steering gear and remove the intermediate shaft boot from the vehicle. Important: Note the relationship of the intermediate shaft to the power steering gear and the intermediate shaft to the steering column in order to ensure proper installation. 13. Remove the lower intermediate shaft to the power steering gear input shaft pinch bolt. 14. Disconnect the lower intermediate shaft from the power steering gear. 15. Remove the lower intermediate shaft from the vehicle. 16. Replace the lower intermediate shaft, P/N 15155707. Parts Information Warranty Information Page 3523 Body Control Module (BCM) C3 Part 2 Page 5703 Left Side Control Valve Body Assembly Diagrams Throttle Body Page 1966 Drive Belt: Testing and Inspection - Symptoms - Drive Belt Drive Belt Chirping See: Drive Belt Chirping Drive Belt Squeal See: Drive Belt Squeal Drive Belt Whine See: Drive Belt Whine Drive Belt Rumbling See: Drive Belt Rumbling Drive Belt Vibration See: Drive Belt Vibration Drive Belt Falls Off See: Drive Belt Falls Off Drive Belt Excessive Wear See: Drive Belt Excessive Wear Drive Belt Tensioner See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Page 10043 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 11793 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 1079 Lock Cylinder Switch: Description and Operation IGNITION LOCK CYLINDER CASE, INCLUDING THE PASSLOCK(TM) SENSOR The ignition lock cylinder fits inside the ignition lock cylinder case and operates the ignition switch when turned by a key with the proper mechanical cut. When the ignition key is used to turn the ignition lock cylinder to crank, start, a magnet on the lock cylinder passes close to the Passlock(TM) Sensor within the ignition lock cylinder case. The magnet activates the Security Hall Effect Sensor in the Passlock(TM) Sensor which completes a circuit from the security sensor signal circuit through a resistor to the security sensor low reference circuit. The resistance value will vary from vehicle to vehicle. If a magnet from outside of the ignition lock cylinder case is used to attempt to steal the vehicle, the Tamper Hall Effect Sensor will be activated. This completes a circuit from the security sensor signal circuit through a tamper resistor to the security sensor low reference circuit bypassing the security resistor. If the ignition switch is forced to rotate without the correct key, or if the ignition lock cylinder is removed by force, the Passlock(TM) Sensor will be damaged and will not operate. Page 10050 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 8703 For vehicles repaired under warranty, use the table. Disclaimer A/T - Key Will Not Release From Ignition Lock Cylinder Automatic Transmission Shift Boot: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 5134 Shift Solenoid: Diagrams 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Slde Page 1906 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 9497 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 2180 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the EFS connectors to both (2) EFS's. 3. Install the CPAs to both EFS connectors. 4. Install sensor bracket to bumper. 5. Install the grille. 6. Install the SIR fuse into the fuse block (1) located in the underhood fuse block. 7. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 1. Remove the key from the ignition. Page 1427 Engine Oil Level And Temperature Sensor Page 6339 8. Remove the brake pad retaining clips from the mounting bracket, inboard brake pad shown. 9. Remove the brake caliper mounting bracket retaining bolts, lower bolt shown. 10. Remove the brake caliper mounting bracket. Heated Oxygen Sensor (HO2S) 1 Replacement Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 1 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). 2. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must install the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. 2. Install the heated oxygen sensor (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Page 3440 Page 11538 Structural Brace: Service and Repair Frame Brace Replacement (Trailblazer, Envoy, Bravada) Frame Brace Replacement (Trailblazer, Envoy, Bravada) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the 2 mounting bolts from the frame brace. 3. Remove the frame brace from the frame. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the frame brace to the frame using the 2 mounting bolts. Tighten the bolts to 50 N.m (37 lb ft). 2. Lower the vehicle. Page 10664 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 9233 Disclaimer Page 13644 License Plate Lamp: Service and Repair LICENSE LAMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the 2 screws that retain the license lamp lens to the liftgate. 2. Remove the license lamp lens from the liftgate. 3. Remove the bulb (1) from the socket. INSTALLATION PROCEDURE 1. Install the bulb (1) to the socket. 2. Wipe the bulb to ensure the bulb is free of dirt or oil. Service and Repair Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement Removal Procedure Properly support the frame when you change the body mounts. If only one mount is changed, lower the entire side on which the mount in placed in order to provide clearance for the mount. 1. Raise the vehicle slightly on a hoist. Refer to Vehicle Lifting. 2. Place jack stands under the body on the side of the vehicle that the mounts will be placed. 3. Remove the body mount bolt, retainer, and lower cushion (1) from the radiator support. 4. Remove the body mount bolts, retainers, and lower cushions (1) from the 5 other mount locations. 5. Lower the hoist enough in order to leave the body supported by the jack stands. 6. Remove the upper cushions (2) from the vehicle. Installation Procedure 1. Install the upper cushions (2) to the vehicle. 2. Raise the frame slightly on the hoist. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the lower cushions, retainers, and bolts to the 5 body mount locations. Tighten the bolts to 80 N.m (59 lb ft). Page 10250 Audio Amplifier C1 (With RPO Code UQA) Part 2 Page 12728 Front Door Weatherstrip: Service and Repair Weatherstrip Side Retainer Replacement Weatherstrip Side Retainer Replacement Removal Procedure 1. Open the front door. Remove the push pin retainers (2) from the front door sealing weatherstrip located at the base of the pillar. 2. Pull back the front door sealing weatherstrip (1) in order to expose the weatherstrip side retainer screws (2). 3. Remove the screws from the weatherstrip side retainer. 4. Remove the weatherstrip side retainer from the windshield pillar. Installation Procedure 1. Install the weatherstrip side retainer (2) to the windshield pillar. Page 1303 Page 13207 Oil Change Reminder Lamp: Service and Repair GM OIL LIFE SYSTEM RESETTING When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL message will come on. Change the engine oil as soon as possible within the next 600 miles (1000 km). It is possible that, if driving under the best conditions, the oil life may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system us ever reset accidentally, change the engine oil at 3000 miles (5000 km) since last oil change. With the Driver Information Center (DIC) 1. Press the fuel information button until ENGINE OIL LIFE appears in the display. 2. To reset the monitor, press and hold the select button while ENGINE OIL LIFE is displayed. Without the Driver Information Center (DIC) To reset the CHANGE ENGINE OIL light, do the following: 1. Turn the ignition key to RUN, with the engine off. 2. Full press and release the accelerator pedal slowly 3 times within 5 seconds. 3. If the CHANGE ENGINE OIL light flashes for five seconds, the system is reset. If the light does not flash, repeat the procedure. 4. Turn the key to LOCK. If the CHANGE ENGINE OIL light comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the procedure. Specifications Valve Guide Seal: Specifications Valve Stem Clearance - Intake 0.0011-0.0025 inch Valve Stem Clearance - Exhaust 0.0015-0.0030 inch Page 4893 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE 1. Install the knock sensor (1 or 2) and the bolt (3). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 13230 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 6937 Application Table Part 2 Page 3782 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the fuel pressure service connection cap. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Install the fuel tank shield if removed. A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Page 12067 WA813K/89 - WA817K/63 Page 4742 Tighten the clamps to 2.5 N.m (22 lb in). 17. Lower the vehicle. 18. Install the fuel fill pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the fuel fill pipe housing. 20. Install the fuel fill cap. Parts Information Parts are expected to be available from GMSPO on August 13, 2004. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 42 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 12196 Front Passenger Door Module (FPDM) - C1 Page 9899 Page 12355 Memory Seat Module - Driver C2 Part 2 A/T - Oil Cooler Flushing Frequently Asked Questions Transmission Cooler: All Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Electrical - Intermittent Interior Electrical Concerns Turn Signal Flasher: All Technical Service Bulletins Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 3653 Manifold Absolute Pressure (MAP) Sensor Page 9368 Abbreviations And Meanings Part 2 Page 7551 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 10879 Abbreviations And Meanings Part 15 Page 9673 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 12613 Position Sensor - Rear Motor (w/Memory) Page 4968 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Page 6943 Application Table Part 4 Location View Page 8340 Page 6796 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 6327 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 2346 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 848 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Service and Repair Pinion Flange: Service and Repair Drive Pinion Flange/Yoke and/or Oil Seal Replacement Tools Required ^ J8614-01 Flange and Pulley Holding Tool ^ J33782 Pinion Oil Seal Installer ^ J38694 Extension Housing Oil Pump/Seal Installer Removal Procedure Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the rear brake calipers. 4. Remove the brake rotors. 5. Remove the propeller shaft. 6. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion oil seal ^ The differential case bearings ^ The axle bearings ^ The axle seals 7. Place an alignment mark between the pinion and the pinion yoke. Page 4296 Registered And Non-Registered Trademarks Part 4 Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: All Technical Service Bulletins Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 1862 Disclaimer Page 12873 Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 2791 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 854 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 690 Sunroof / Moonroof Module: Diagrams Sunroof Module C1 Page 6830 Starter Motor Usage Page 7271 Abbreviations And Meanings Part 7 Page 13198 Page 10521 Page 236 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 12563 Registered And Non-Registered Trademarks Part 5 Page 7784 7. Disconnect the lower intermediate shaft boot from the power steering gear and remove lower intermediate shaft boot from the vehicle. 8. Raise and support the vehicle. Important: Note the relationship of the intermediate shaft to the power steering gear and the intermediate shaft to the steering column in order to ensure proper installation. 9. Remove the lower intermediate shaft to the power steering gear input shaft pinch bolt. 10. Disconnect the lower intermediate shaft from the power steering gear. 11. Remove the lower intermediate shaft from the vehicle. Installation Procedure Page 3809 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Camshaft Actuator System Camshaft Position Sensor: Description and Operation Camshaft Actuator System CAMSHAFT POSITION (CMP) ACTUATOR SYSTEM The Camshaft Position Actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation control, a wider engine torque range, improved gas millage, and improved engine idle stability. The CMP Actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. CMP ACTUATOR SYSTEM OPERATION The CMP Actuator system is controlled by the Powertrain Control Module (PCM). The PCM sends a pulse width modulated 12 volt signal to a Camshaft Position (CMP) Actuator Solenoid in order to control the amount of engine oil flow to a cam Phaser passage. There are two different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The Cam Phaser is attached to a camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position. Engine oil pressure, viscosity, temperature and engine oil level can have an adverse affect on cam phaser performance. The PCM calculates the optimum cam position through the following inputs: Engine Speed - Manifold Absolute Pressure (MAP) - Throttle Position (TP) Indicated Angle - Crankshaft Position (CKP) - Camshaft Position (CMP) - Engine Load. - Barometric (BARO) Pressure The Cam Phaser default position is 0 degrees. The PCM uses the following inputs before assuming control of the cam phaser: Engine Coolant Temperature (ECT) - Closed Loop Fuel Control - Engine Oil Temperature - Engine Oil Pressure - Engine Oil Level - CMP Actuator Solenoid circuit state - Ignition 1 signal voltage - Barometric (BARO) Pressure CMP ACTUATOR SOLENOID CIRCUIT DIAGNOSTICS The PCM monitors the control circuits of the CMP Actuator Solenoid for electrical faults. The PCM has the ability to determine if a control circuit is open, shorted high, and shorted low. If the PCM detects a fault with a CMP Actuator Solenoid circuit a Diagnostic Trouble Code (DTC) will set. CMP ACTUATOR SYSTEM PERFORMANCE DIAGNOSTICS The PCM monitors the performance of the CMP Actuator system by monitoring the actual and desired positions of a cam phaser. If the difference between the actual and desired position is more than a calibrated angle for more than a calibrated amount of time, a DTC will set. Page 13322 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front passenger side seat. 2. Remove the park brake warning lamp switch electrical connector. 3. Remove the park brake warning lamp switch retaining screw. 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch retaining screw. ^ Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). 3. Connect the electrical connector. 4. Install the front passenger side seat. Page 586 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 10120 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 7596 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Locations Park Neutral Position (PNP) Switch Locations Park Neutral Position (PNP) Switch Page 2803 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 6671 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. A/T - Key Will Not Release From Ignition Lock Cylinder Automatic Transmission Shift Boot: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 11217 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Opening Weatherstrip Replacement - Rear Door Opening Removal Procedure 1. Remove the rear door sill plate. 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. Page 13017 Abbreviations And Meanings Part 18 Page 10354 Abbreviations And Meanings Part 7 Page 1793 Windshield Washer Fluid Reservoir Page 12378 Seat Recline Motor - Driver/Passenger Page 8751 Low Pressure Sensor / Switch: Locations Engine Compartment, Right Rear (w/Manual HVAC System) Engine Compartment, Right Rear (w/Automatic HVAC System) Page 4620 Steps 6-8 The number below refers to the step number on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. Page 7740 Important: The boot (1) must not be twisted, puckered or out of shape in any way. If the rack and pinion boot (1) is not shaped properly, adjust by hand before installing the boot clamps (3,4). Be sure arrows on the boot (1) align with range on the gear housing. 6. Crimp the large seal retaining clamp (4) on boot (1) with J22610. 7. Crimp the small seal retaining clamp (3) to inner tie rod assembly (2) with J22610. 8. Install the rack and pinion gear. 9. Install the outer tie rod. Page 569 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 6141 Brake Bleeding: Service and Repair Manual Bleeding Procedure Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7- 11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Page 4405 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Page 3853 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Locations Door Lock Switch, Window Switch, Driver Door Module (DDM) Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Page 6172 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 4233 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 1940 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils Page 6861 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 7954 3. Remove the fuel fill pipe bracket nut (2). 4. Raise and suitably support the vehicle. 5. Remove the fuel fill pipe ground strap bolt. 6. Cut off the ground strap ring terminal and tie strap. 7. Loosen the fuel hose clamp (8). 8. Remove the fuel fill upper pipe (7) from the vehicle. 9. Install the new fuel fill upper pipe into the vehicle. Use P/N 88983256 for 2002-2003 model year vehicles or P/N 15131043 for 2004 model year vehicles. 10. Tighten the fuel hose clamp. Tighten Tighten the clamp to 2.5 N.m (22 lb in). 11. Wrap the excess length of ground strap around the fuel hose as necessary. 12. Install the fuel fill pipe ground strap bolt in its original location. 13. Loosen the fuel hose clamps (1, 3). 14. Remove the lower fuel hose (2) from the vehicle. 15. Install the new lower fuel hose into the vehicle. 16. Tighten the lower fuel hose clamps. Tighten Page 4315 Body Control Module: Removal and Replacement Body Control Module Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. Do not open the BCM housing. The module does not have any serviceable components. The module may be replaced only as an assembly. 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the BCM on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the BCM on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. Page 8320 32. Install the new hose (1), # 1005 (L6 engine) or# 1006 (V8 engine) onto the coolant bypass valve at the location the above hose was removed. The other end of this hose will be installed on the auxiliary heater pump outlet port. Page 889 Body Control Module: Connector Views Body Control Module (BCM) C1 Part 1 Page 2216 Fuse Block - Rear C1 Part 6 Fuse Block - Rear C2 Fuse Block - Rear C2 Part 1 Service and Repair Sunroof / Moonroof Windguard: Service and Repair SUNROOF WINDOW WEATHERSTRIP REPLACEMENT REMOVAL PROCEDURE 1. Remove the sunroof window. 2. Carefully remove the sunroof window weatherstrip from the perimeter of the sunroof window. INSTALLATION PROCEDURE 1. Carefully install the sunroof window weatherstrip to the perimeter of the sunroof window, ensuring that the weatherstrip is fully seated. 2. Install the sunroof window to the sunroof module assembly. 3. Ensure that the sunroof does not have any air or waterleaks. Page 6896 Abbreviations And Meanings Part 11 Page 9920 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Diagrams Blower Motor Resistor Assembly Page 2226 Fuse Block - Rear C4 Part 2 Page 12827 Abbreviations And Meanings Part 4 Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Page 3129 Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... ................................................ 18.0 Nm (13.0 lb. ft.) Spark Plug Gap ................................................ ..................................................................................................................................... 1.08 mm (0.0425 in.) Page 3749 Steps 10-13 Page 234 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 8246 2. Disconnect the electrical connector from the mode actuator. 3. Remove the screws from the mode actuator (3). 4. Remove the mode actuator. INSTALLATION PROCEDURE 1. Install the mode actuator (3). 2. Install the screws to the mode actuator (3). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the mode actuator electrical connector. 4. Install the I/P carrier. 5. Calibrate the air temperature actuator on vehicles equipped with automatic climate control (C68), See: Testing and Inspection/Programming and Relearning Mode Actuator - Auxiliary MODE ACTUATOR REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. Page 11343 Endgate Module (EGM) C2 (XUV) Part 1 Page 2278 Application Table Part 4 Location View Page 10523 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 601 Abbreviations And Meanings Part 13 Page 8862 Forward Lamp Harness, Right Side Page 2930 Abbreviations And Meanings Part 2 A/T - Transmission Mount Availability Transmission Mount: Technical Service Bulletins A/T - Transmission Mount Availability Bulletin No.: 04-07-30-035 Date: August 11, 2004 INFORMATION Subject: Release of Rear Transmission Mount Separate From Exhaust Mount Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) The purpose of this service bulletin is to announce the availability of the rear transmission mount without the exhaust mount bracket included. Previously when ordering the rear transmission mount from GMSPO, it could only be ordered with the exhaust mount bracket included. Currently, you can order the rear transmission mount without the exhaust mount bracket from GMSPO. When service requires the replacement of only the rear transmission mount and not the exhaust mount, order P/N 89040449 (2WD) and P/N 89040448 (4WD). Page 8806 Ambient Air Temperature Sensor Page 5822 Tighten the nut in small increments, as needed, until the rotating torque is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft. 11. Install the brake rotors. 12. Install the brake calipers. 13. Install the tire and wheel assemblies. 14. Inspect and add axle lubricant to the axle housing, if necessary. Page 7487 C309 (Long Wheelbase, Body Type VIN 6) Part 1 Page 13160 Registered And Non-Registered Trademarks Part 6 Page 7372 Application Table Part 2 Page 12202 Door Control Module Diagram 2 Page 6198 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Steering Gear Crossmember Replacement - Front Cross-Member: Service and Repair Steering Gear Crossmember Replacement - Front Steering Gear Crossmember Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield mounting bolts. 3. Remove the engine shield. 4. Remove the rear lower control arm bracket to frame mounting bolts. 5. Remove the steering gear crossmember mounting bolts. 6. Remove the steering gear crossmember. Installation Procedure Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 2761 Page 4666 5. Connect the fuel feed and return pipes (1, 2) to the fuel rail. 6. Connect the fuel injector electrical connectors. 7. Connect the fuel pressure regulator vacuum line. 8. Install the intake manifold. 9. Connect the negative battery cable. 10. Inspect for leaks. 10.1. Turn ON the ignition, with the engine OFF for 2 seconds. 10.2. Turn OFF the ignition for 10 seconds. 10.3. Turn ON the ignition, with the engine OFF. 10.4. Inspect for fuel leaks. Page 7937 For vehicles repaired under warranty, use the table. Disclaimer Page 7661 16. Connect the power steering hose assembly to the power steering gear. 17. Install the power steering hose assembly to power steering gear retaining bolt. Tighten the power steering hose assembly to power steering gear retaining bolt to 12 Nm (106 inch lbs.). 18. Remove the drain pan from under the vehicle. 19. Lower the vehicle. 20. Bleed the power steering system. Page 10837 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 10031 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 6650 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 6564 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure Page 10661 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 12034 WA8555/41 - WA8624/50 Initial Inspection and Diagnostic Overview Heated Glass Element: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Heated Glass Element DIAGNOSTIC STARTING POINT - HEATED GLASS ELEMENT For the inside rearview mirror with the automatic day-night feature, begin the diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Heated Glass Element in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures For the rear window defogger, begin the diagnosis with the Diagnostic System Check - Defogger. The Diagnostic System Check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Defogger DIAGNOSTIC SYSTEM CHECK - DEFOGGER TEST DESCRIPTION Page 7707 For vehicles repaired under warranty, use the table. Disclaimer Body - Door Mirror Actuator Replacement Power Mirror Motor: Technical Service Bulletins Body - Door Mirror Actuator Replacement Info - Availability of Replacement Mirror Actuator # 03-08-64-033 (09/11/2003) Availability of Replacement Mirror Actuator Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2003 Oldsmobile Bravada A replacement mirror actuator is available for service. It is no longer necessary to replace the mirror assembly for an actuator. Use the following procedure to replace the actuator. 1. Rotate the mirror into the upward and outboard position. See the illustration above. 2. Position your fingers flat and insert them underneath the raised corner. This will ensure that more surface of the mirror is used when removing the glass. See the illustration above. 3. Slowly but firmly lift the glass and backing plate from the actuator. 4. Remove the wire harness from the glass if equipped with heated mirror and turn signal. 5. Remove the glass. 6. Remove the three torque head screws from the actuator. 7. Remove the actuator. 8. Remove the wire harness from the actuator. 9. Install the wire harness to the new actuator. 10. Install the new actuator. Engine Controls - Above Normal Temp. Gauge Readings Temperature Gauge: All Technical Service Bulletins Engine Controls - Above Normal Temp. Gauge Readings Bulletin No.: 04-06-02-005 Date: July 27, 2004 TECHNICAL Subject: Higher Than Normal Engine Coolant Temperature Gauge Readings (Reprogram PCM) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on higher than normal engine coolant temperature gauge readings when operating the vehicle in very high outside ambient temperatures, and in stop and go or slow moving traffic. Cause Reduced air flow across the radiator and preheated air from stopped or slow moving driving conditions from traffic congestion may result in normally higher engine coolant operating temperatures as indicated by the temperature gauge. Correction Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 7.3 available July 7, 2004. As always, make sure your TECH 2(R) is updated with the latest software version. This new calibration will cause the PCM to command small amounts of additional fan engagement to control engine coolant temperatures and gauge readings closer to a customer perception of normal. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5304 Tighten the nut to 10 N.m (89 lb in). 19. Reposition the A/C line into place. 20. Install the A/C line bracket to the oil level indicator tube stud and secure the bracket with the nut. 21. Install the A/C line bracket to the engine lift bracket and secure the A/C bracket with the bolt. Tighten ^ Tighten the A/C line bracket nut to 7 N.m (62 lb in). ^ Tighten the A/C bracket bolt to 10 N.m (89 lb in). 22. Reinstall the air cleaner outlet duct. 23. Install the new fluid level indicator, P/N 15069769. 24. Check the transmission fluid level. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 3924 Abbreviations And Meanings Part 11 Page 9956 Disclaimer Page 6437 Page 8859 approximately 25 mm (1 in) away from the connector so the wires can be fed into the slot. Feed the wires into the slot and install the harness to the plastic guide. Connect the harness electrical connector to the cooling fan clutch. Install the cooling fan. Refer to the Cooling Fan and Shroud Replacement procedure in the Engine Cooling sub-section of SI. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 6509 2. Position the shoe (2) on the actuation mechanism. 3. Holding the lower end of the shoe (2) away from the backing plate, slide the shoe down, over the top of the hold down spring (3). 4. Place the lower end of the shoe (2) against the backing plate. 5. Slide the shoe (2) up and under the hold down spring (3). 6. Inspect the position of the shoe assembly. The shoe must be central on the backing plate and with both tips located in the slots of the actuation mechanism (1). 7. Manually check the park brake for proper operation by moving the park brake actuator lever and observing the movement of the actuation mechanism. 8. Install the park brake cable to the park brake lever. 9. Adjust the park brake shoe (1). 10. Install the brake rotor. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: Customer Interest Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 1168 Caution: Refer to Brake Fluid Irritant Caution in Cautions and Notices. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices. 1. Remove the air cleaner intake duct. 2. Disconnect the electrical connector from the fluid level sensor. 3. Using a pair of needle nose pliers, compress the locking tabs on the fluid level sensor Page 11646 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Locations Engine Page 6293 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Page 9616 Page 11358 Do not use oxyacetylene welding equipment. MIG WELD ONLY. Weld the crack/four holes that were drilled through the inner panel using the appropriate welding technique. Prior to refinishing, refer to the GM4901M-D-2006 (English) or GM4901M-D-F2006 (French) GM Approved Refinish Materials booklet for recommended products. The GM Refinish Materials information is now on the GMGOODWRENCH WEB SITE ONLY. Printed books have been discontinued. Steps to the site are as follows: Go to www.gmgoodwrench.com. Click on GM Parts and Accessories link. Click on GM Technical Repair Information. Click on Paint Shop. Clean and prepare all of the welding surfaces. Return the surface to its original contour. Spot paint and clear the area around the hinges. Reinstall the liftgate. Replace the upper two bumpers and inspect the lower two bumpers. Replace as necessary. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12478 2. Remove the rear seat bracket trim covers (1). 3. Remove the rear seat bracket mounting nuts (2). 4. Remove the rear seat bracket. 5. Remove the two bolts (2) securing the support (1) to the seat cushion trim panel. 6. Remove the seat cover J-strips (1) from the seat cushion trim panel (2). 7. Remove the screws securing the seat cushion trim panel to the seat frame. 8. Remove the seat cushion trim panel. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the screws securing the seat cushion trim panel to the seat cushion assembly. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 11928 Memory Seat Switch, Driver Door Module (DDM) - C4 Body - Rear License Plate Pocket Gasket is Loose License Plate Bracket: All Technical Service Bulletins Body - Rear License Plate Pocket Gasket is Loose Bulletin No.: 04-08-66-001E Date: December 13, 2007 TECHNICAL Subject: Rear License Plate Pocket Perimeter Gasket Loose/Out of Position Or Excessive Amount Of Adhesive (Install New Gasket Using Updated Retainer Tightening Sequence) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2008 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and change the part numbers. Please discard Corporate Bulletin Number 04-08-66-001D (Section 08 - Body & Accessories). Condition Some customers may comment that the insulating perimeter seal or gasket on the backside edge of the license plate housing/pocket appears to be shrinking or becomes pulled away from the edge of the license plate housing/pocket. Some customers may also comment about excessive amounts of adhesive oozing from the gasket. Cause This condition may be caused by changes in temperature, which may cause the plastic license plate housing to expand and contract. When this occurs, the license plate housing gasket seal may be caught and pulled under the housing/pocket. Correction A new gasket without the adhesive has been released for service. Technicians are to replace the rear license plate pocket perimeter gasket using the following procedure: Excessive amounts of adhesive, which may have oozed from the gasket, may be cleaned using GM Tar and Road Oil Remover, P/N 1050172 (in Canada, P/N 992856), or the equivalent. Remove the rear license plate pocket assembly. Refer to the License Plate Pocket Replacement procedure in the Body Rear End (2006 MY and prior) or Exterior Trim sub-section of SI. Remove the rear license plate pocket perimeter gasket. Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Locations Impact Sensor: Locations Locations View Page 11843 Registered And Non-Registered Trademarks Part 2 Page 1972 Drive Belt Vibration Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Page 1535 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE 1. Install the knock sensor (1 or 2) and the bolt (3). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 10046 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Electrical Specifications Fuel Injector: Electrical Specifications Fuel Injector Resistance ...................................................................................................................... ............................................................. 11 - 14 Ohms Page 1040 Page 12858 Audible Warning Device: Description and Operation AUDIBLE WARNINGS DESCRIPTION AND OPERATION The audible warnings alert the driver of a system concern or a critical vehicle condition. The radio generates the audible warnings through the left front speaker. The radio receives audible warning requests via the class 2 serial data line. If the radio receives multiple audible warning requests, the warning with the highest priority sounds first. On vehicles with RPO UQA the audio amplifier, instead of the radio, generates the audible warnings and receives audible warnings requests via the class 2 serial data line. Either the radio or the audio amplifier is the chime producer. The following lists the audible warning priority and the pulse rate: 1. Fast rate chime (200 pulses per minute) 2. Medium rate chime (150 pulses per minute) 3. Slow rate chime (50 pulses per minute) 4. Single chime DOOR AJAR WARNING The chime producer activates the door ajar audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime duration (4 pulses). The door ajar warning sounds and the appropriate DOOR AJAR indicator illuminates in the Driver Information Center when the following occurs: The body control module (BCM) determines that a door (driver door, passenger door, left rear door, right rear door) is open and the signal circuit is low. The IPC receives a class 2 message from the BCM indicating the door ajar status. - The vehicle is not in park. The IPC receives a class 2 message from the PCM indicating the gear position. - The vehicle speed is greater than 8.05 km/h (5 MPH). The IPC uses the vehicle speed signal circuit (4000 pulses/mile) from the PCM in order to calculate the vehicle speed. FASTEN SAFETY BELT WARNING The chime producer activates the fasten safety belt audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the duration (8 seconds). The fasten safety belt warning sounds and the fasten safety belt indicator illuminates when the following occurs: The ignition switch transitions to ON. - The inflatable restraint sensing and diagnostic module (SDM) detects that the driver's seat belt is not buckled (signal is low). The IPC receives a class 2 message from the SDM indicating the driver's seat belt status. If the seat belt is buckled when the ignition is turned on, the chime does not sound. If the seat belt is buckled while the chime is sounding, the chime stops. If the seat belt is unbuckled after the initial transition to ON, the chime does not sound. KEY-IN-IGNITION WARNING The chime producer activates the key-in-ignition audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration (continuous). The key-in-ignition warning sounds when the following occurs: The ignition switch is OFF. - The body control module (BCM) determines that the driver's door is open and the signal circuit is low. The IPC receives a class 2 message from the BCM indicating the door ajar status. - The BCM determines that the key-in-ignition switch is closed and the signal circuit is low. The IPC receives a class 2 message from the BCM indicating the key-in-ignition status. LIGHTS ON WARNING The chime producer activates the lights on warning as requested by the body control module (BCM). The BCM sends a class 2 message to the chime producer indicating the chime frequency (fast rate) and duration (continuous). The lights on warning sounds when the following occurs: The ignition is OFF. - The BCM determines that the driver's door is open and the signal circuit is low. - The BCM determines that the headlamp switch is in the park or head position. ADDITIONAL WARNINGS The following warnings have an associated IPC indicator or DIC indicator: Check Oil Level The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration. - Liftgate Ajar / Rear Access Open The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration (4 pulses). - Low Fuel The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency (medium rate) and duration (4 pulses). - Oil Pressure Low Stop Engine The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration. - Overspeed / Vehicle Overspeed The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration (continuous). Page 1491 For vehicles repaired under warranty, use the table. Disclaimer Locations Electronic Components Page 13976 Steps 1-7 Page 8389 Abbreviations And Meanings Part 9 Page 8986 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Page 14003 Page 2083 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Page 13624 Headlamp Leveling Actuator - Right (With RPO Code TR6) Page 3868 Page 10391 Steps 1-2 Connector Views Data Link Connector (DLC) Page 11842 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 1213 Oil Pressure Sensor: Diagrams Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Page 6004 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON(R) transmission fluid. Page 12911 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 1695 Page 3167 For vehicles repaired under warranty, use the table. Disclaimer Page 9636 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 833 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 13917 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 13967 Heated Glass Element: Description and Operation REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION REAR WINDOW DEFOGGER SYSTEM COMPONENTS The rear window defogger system consist of the following components: HVAC control module - Liftgate module (LGM) - Rear window defogger grid REAR WINDOW DEFOGGER OPERATION Battery positive voltage is supplied through the LGM 2 fuse to the LGM for the rear window defogger system. When you turn the ignition to the ON position, and the rear window defogger switch is depressed. The HVAC control module illuminates the rear window defogger indicator and sends a class 2 message to the LGM to enable the rear window defogger system. The LGM enable the rear window defogger system by allowing battery positive voltage to the rear window defogger. When you turn ON the ignition and press the rear window defogger switch for the first time, the defogger cycle lasts 10 minutes. Further operation results in 10 minute defogger cycles. Page 8338 Page 3483 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 9833 Abbreviations And Meanings Part 25 Page 5944 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Page 2929 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 1432 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield. 3. Remove the electrical connector from the oil pressure switch. 4. Remove the oil pressure switch. Installation Procedure NOTICE: Refer to Fastener Notice in Service Precautions. See: Engine, Cooling and Exhaust/Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the oil pressure switch. Tighten the oil pressure switch to 20 Nm (15 ft. lbs.). 2. Install the electrical connector to the oil pressure switch. 3. Install the engine shield. 4. Lower the vehicle. Page 260 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 6215 Abbreviations And Meanings Part 14 Page 3515 Registered And Non-Registered Trademarks Part 6 Page 9546 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 2943 Abbreviations And Meanings Part 15 Page 13269 Abbreviations And Meanings Part 7 Service and Repair PCV Valve Hose: Service and Repair Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Removal Procedure 1. Disconnect the crankcase dirty air hose from the intake manifold. 2. Disconnect the crankcase dirty air hose from the positive crankcase ventilation (PCV) orifice tube. 3. Loosen the throttle body clamps (2). 4. Disconnect the fuel pressure regulator vacuum supply hose from the air cleaner outlet resonator. Page 1039 20. Remove the backing material from the seal, align it over the wiper motor cover so that it completely covers the vent (2), and press it firmly into place as shown in the above illustration. Apply firm pressure across the entire surface of the seal and around all outside edges. Continue applying pressure a second time to the edges to assure full adhesion. 21. Position the wiper module to the vehicle and connect the electrical connector. 22. Install the wiper module in the plenum sheet metal. 23. Install the two 10 mm hex head bolts that attach the module to the plenum sheet metal. Tighten Tighten the bolts to 8 N.m (71 lb in). 24. Install the air inlet grille to the plenum sheet metal. 25. Install the 10 mm hex head nut that attaches the left and right ends of the air inlet grille to the plenum sheet metal. Tighten Tighten the nuts to 4 N.m (35 lb in). 26. Install the antenna mast. Important If installing a NEW wiper module, you must verify that the new wiper motor and transmissions are in the PARK position before installing the wiper arms. 27. If installing a NEW wiper module, turn the ignition switch to the ON position, turn the wiper switch ON, and visually verify that the wiper transmissions operate. After visually verifying operation, turn the wiper switch to the OFF position and allow the wiper transmissions to stop moving before turning the ignition switch to the OFF position. The wiper motor will now be in the PARK position. 28. Using the marks or masking tape that were placed on the windshield, align and position the wiper arms on the wiper transmission shafts. 29. Install the nuts on the wiper transmission shafts. Tighten Tighten the nuts to 30 N.m (22 lb ft). 30. Install the covers on the wiper arm nuts. 31. Remove the marks or masking tape from the windshield. 32. Open the hood. 33. Install the three push-in retainers that attach the air inlet grille to the plenum sheet metal. 34. Close the hood. 35. Verify that all functions of the wiper system (low, high, delay, etc.) operate properly. Page 5332 8. Install the oil pan drain plug, if equipped. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 1249 Instrument Panel Carrier-Air Duct B-Pillar, Left Page 8377 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 11815 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Data Link Connector (DLC) and Splice Pack SP205 Data Link Connector (DLC) And Splice Pack SP205 Electrical - Proper Jump Starting Procedure Jump Starting: Technical Service Bulletins Electrical - Proper Jump Starting Procedure Bulletin No.: 04-06-03-005A Date: May 17, 2006 INFORMATION Subject: Proper Connection Information to Avoid Blown 125 Amp Fuse and Various Interior Electrical System Conditions When Jump Starting Vehicle Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2007 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-06-03-005 (Section 06 - Engine/Propulsion System). It has been found that some dealers may be using the IP battery positive stud at the underhood fuse block to jump start the vehicle. This bulletin is being issued to inform dealers that investigation has indicated the 125 amp mega fuse (no. 48) located in the engine compartment fuse block may be blown resulting in various electrical system conditions due to using this improper connection. To properly jump start the vehicle, you must always use the following connections. For the positive connection, use the battery terminal. For the negative connection, use the remote terminal located on the front engine lift bracket (marked "GND"). Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 7524 9. Install the 3 bolts (1) that retain the junction block to the block base. Tighten Tighten the 3 bolts to 3.5 N.m (31 lb in). 10. Install the BCM to the rear electrical center. 11. Install the battery feed terminal nut (2) to the junction block. Tighten Tighten the battery feed terminal nut to 10 N.m (88 lb in). 12. Install the rear electrical center cover. 13. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a passenger position. 14. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 15. Connect the battery negative cable. Page 5810 1. Install the rear axle drain plug. Tighten the rear axle drain plug to 48 Nm (35 ft. lbs.). 2. Fill the rear axle with axle lubricant. Use the proper fluid. 3. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 4. Lower the vehicle. Page 663 Memory Seat Module - Driver C4 Part 2 Page 13302 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front passenger side seat. 2. Remove the park brake warning lamp switch electrical connector. 3. Remove the park brake warning lamp switch retaining screw. 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch retaining screw. ^ Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). 3. Connect the electrical connector. 4. Install the front passenger side seat. Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Press tabs (1) inward and lift to remove the junction block cover. 3. Pull upward on the fuse relay center cover (1) to release the retaining tabs and remove the cover. 4. Note the location and remove the harness end bolts (2) and remove the harness ends from the fuse relay center. 5. Remove the fuse relay center bolts (3) and remove the fuse relay center from the junction block bracket. 6. Pull downward on the wiring harness ends to remove from the bottom of the fuse relay center. Page 12879 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 3433 Body Control Module (BCM) Page 9866 Global Positioning System Antenna: Service and Repair Coupling Replacement - Antenna Outer COUPLING REPLACEMENT - ANTENNA OUTER REMOVAL PROCEDURE 1. Install the inner coupling first, if both the inner and outer couplings are to be replaced. IMPORTANT: The adhesion promoter must be used to assure adequate bonding of the coupling. - To obtain maximum adhesion between the new cellular antenna couplings and the glass surface, the cellular antenna couplings and the glass must be kept dry and above 15°C (60°F) during the installation, and for 24 hours immediately following the installation. Otherwise the new couplings may not remain on the glass. - Do not attempt to reinstall the original couplings using any type of glue, adhesive tapes, etc. Doing so, may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Use a thin, wide-bladed plastic tool to cut the double back tape material, while lifting up on the outer antenna coupling. INSTALLATION PROCEDURE 1. Clean the outside of the back glass with alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. 3. Apply Glass Adhesion Promoter GM P/N 12378555 (Canadian P/N 88901239) to the back glass in the area the antenna coupling is to be installed. Follow the Glass Adhesion Promoter instructions on the product label. IMPORTANT: The adhesion promoter must be used to assure adequate bonding of the coupling. - Mask or protect the surrounding area before applying the adhesion promoter. Remove the protective film from the adhesive backing on the outer antenna coupling. Electrical - Intermittent Interior Electrical Concerns Hazard Warning Flasher: Customer Interest Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 12304 3. Connect the rear drain sunroof hose to the sunroof module rear spigot, right or left side, as needed. 4. Install the headliner. Page 6990 Location View Page 9676 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 12047 Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Page 6187 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 12032 WA8555/41 - WA8555/41 Page 14005 Page 6298 Page 1311 1. Position the sensor to the trim pad. 2. In order to install the sensor to the trim pad, rotate the sensor clockwise 1/4 turn. 3. Position the trim pad to the upper portion of the instrument panel (IP). 4. Connect the electrical connector to the sensor. 5. Remove the shop rags from the windshield defrost vents. 6. Install the trim pad to the IP. 7. Install the windshield garnish moldings. Page 6601 For vehicles repaired under warranty, use the table. Disclaimer Page 9802 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 2213 Fuse Block - Rear C1 Part 3 Page 12476 7. Carefully separate the hook and loop fastener strips (2) holding the cover to the pad. 8. Remove the hog rings (1). Installation Procedure 1. Install the hog rings (1) securing the seat cover to the pad. 2. Pull the cover over the pad pressing the hook and loop fastener strips (2) together. 3. Install the cover flaps to the pad with hog rings (1). 4. Install the seat cushion panel on the pad and cover. 5. Install the J-strips (2) securing the seat cushion cover to the seat cushion panel. 6. Install the pull handle assembly (1). Notice: Refer to Fastener Notice in Service Precautions. 7. Install the rear seat cushion assembly (1) to the seat latch rod (3) with two bolts (2). Tighten the seat cushion bolts to 11 N.m (97 lb in). Seat Cushion Panel Replacement - Rear No. 2 Seat Cushion Panel Replacement - Rear No. 2 Removal Procedure Page 574 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Knock Sensor (KS) 1 Front Knock Sensor (KS) 1 Front Ignition System - MIL ON/Misfire DTC's In Wet Weather Spark Plug: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 14012 Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ....................................................... 2.65 lb. (1.2 kg.) Page 4343 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4130 Abbreviations And Meanings Part 16 Page 6898 Abbreviations And Meanings Part 13 Page 4014 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6235 Page 12839 Abbreviations And Meanings Part 16 Page 6704 Abbreviations And Meanings Part 26 Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 7827 Ball Joint: Service and Repair Upper Ball Joint Upper Ball Joint Replacement Tools Required ^ J9519-E Lower Ball Joint Remover and Installer ^ J21474-01 Control Arm Bushing Set ^ J45117Ball Joint Installation Spacer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the steering knuckle with wheel hub attached. 4. Remove the upper ball joint retaining clip. 5. Remove the upper ball joint boot. 6. Remove the upper ball joint from the steering knuckle using J9519-E. Installation Procedure Page 9785 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 12615 Seat Lumbar Motors And Position Sensors Assembly - Driver Part 1 Service and Repair Differential Cover: Service and Repair Rear Axle Housing Cover and Gasket Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the rear axle. 3. Remove the rear axle housing cover bolts (1). Important: Do not nick or cut the rear axle housing cover gasket. 4. Remove the rear axle housing cover (2) from the axle housing. 5. Drain the axle lubricant into a suitable container. Installation Procedure 1. Inspect the rear axle cover gasket for nicks, cuts or damage that may cause the gasket to not seal properly. If any of these conditions exist, replace the gasket. 2. If the gasket is to be reused, clean the rear axle housing cover gasket a suitable cleaner. 3. Clean the rear axle housing cover gasket surface and the rear axle housing gasket surface with a suitable cleaner. 4. Install the rear axle housing cover gasket and the rear axle housing cover (2). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the rear axle housing cover bolts (1). ^ For the 8.0 inch axle, tighten the rear axle housing cover bolts in a crosswise pattern to 30 Nm (20 ft. lbs.). ^ For the 8.6 inch axle, tighten the rear axle housing cover bolts in a crosswise pattern to 25 Nm (18 ft. lbs.). 6. Fill the rear axle with axle lubricant. Use the proper fluid. 7. Lower the vehicle. Refer to Vehicle Lifting. Page 6287 WARRANTY INFORMATION Page 10323 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 591 Abbreviations And Meanings Part 3 Page 2200 Application Table Part 2 Page 9341 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 12545 Abbreviations And Meanings Part 13 Page 12567 Heated Seat Element - Front Passenger Cushion Page 1229 Ambient Temperature Sensor / Switch HVAC: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2 wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and low reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0-5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the following conditions: The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Control Module HVAC Control Module HVAC: Service and Repair Control Module HVAC HVAC Control Module Replacement Removal Procedure 1. Remove the I/P accessory trim plate. 2. Remove the HVAC control module screws. 3. Depress the HVAC control module tabs (3) and remove the HVAC control module (2) from the I/P (4). 4. Disconnect the electrical connectors (1) from the HVAC control module (2). Installation Procedure 1. Connect the electrical connectors (1) to the HVAC control module (2). Important: Ensure that the HVAC control module tabs (3) lock into place. 2. Install the HVAC control module (2) into the I/P (4). Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the HVAC control module screws. Tighten the screws to 1.9 Nm (17 in. lbs.). 4. Install the I/P accessory trim plate. Page 12898 5. Tape over the entire cable. Use a winding motion when you apply the tape. Heater Hose - Inlet Heater Hose: Service and Repair Heater Hose - Inlet Body VIN 3 / GMT 360 HEATER HOSE REPLACEMENT - INLET (BODY TYPE VIN 3) TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 2. Using the J 43181, disconnect the inlet heater hose (2) from the heater core inlet tube. 2.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 2.2. Close the tool around the inlet heater core hose. 2.3. Firmly pull the tool into the quick connect end of the heater hose. 2.4. Firmly grasp the heater hose (2). Pull the heater hose forward in order to disengage the hose from the heater core. 3. Position the inlet heater hose clamp (1) at the engine block using J 38185. 4. Remove the heater inlet hose (2) from the inlet hose fitting at the engine block. 5. Remove the heater inlet hose. INSTALLATION PROCEDURE 1. Apply coolant to the end of the heater inlet hose. 2. Install the heater inlet hose (2) to the inlet hose fitting at the engine block. IMPORTANT:When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine Page 2804 Abbreviations And Meanings Part 2 Page 1769 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Heater Hose - Inlet Heater Hose: Service and Repair Heater Hose - Inlet Body VIN 3 / GMT 360 HEATER HOSE REPLACEMENT - INLET (BODY TYPE VIN 3) TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 2. Using the J 43181, disconnect the inlet heater hose (2) from the heater core inlet tube. 2.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 2.2. Close the tool around the inlet heater core hose. 2.3. Firmly pull the tool into the quick connect end of the heater hose. 2.4. Firmly grasp the heater hose (2). Pull the heater hose forward in order to disengage the hose from the heater core. 3. Position the inlet heater hose clamp (1) at the engine block using J 38185. 4. Remove the heater inlet hose (2) from the inlet hose fitting at the engine block. 5. Remove the heater inlet hose. INSTALLATION PROCEDURE 1. Apply coolant to the end of the heater inlet hose. 2. Install the heater inlet hose (2) to the inlet hose fitting at the engine block. IMPORTANT:When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine Page 1126 Seat Adjuster Switch - Driver (w/Memory) Page 3768 Disclaimer Page 8293 3. Remove the air temperature sensor. 4. Disconnect the electrical connector (2) from the upper air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the upper air temperature sensor (1) to the air duct (2). 2. Connect the electrical connector (2) to the upper air temperature sensor (1). 3. Install the upper air temperature sensor. 4. Install the HVAC control module. 5. Install the radio. Upper Right AIR TEMPERATURE SENSOR REPLACEMENT - UPPER RIGHT REMOVAL PROCEDURE 1. Remove the radio. Page 9402 The Timer is started and stopped using the DIC Select button. Holding the Select button for longer than 3 seconds while the Timer parameter is displayed will reset the Timer to 00:00:00. The Timer status and data value is retained in memory when the ignition is turned OFF. When the ignition is turned ON again, the Timer status and data value is resumed. The Timer maximum value is 99:59:59. When the maximum is reached, the Timer rolls over to 00:00:00 and continues to operate. FUEL INFORMATION DIC FUEL INFORMATION / RESET CAPABILITIES The available DIC Fuel Information and reset capabilities are as follows: Range - Can not be reset - Avg. Fuel Economy - Can be reset - Inst. Fuel Economy - Can not be reset - Engine Oil Life - Can be reset RANGE The range display is the estimated distance that the vehicle can travel under current fuel economy and fuel level conditions. This range is calculated from odometer information and class 2 messages. Fuel Range is capable of displaying values from 0 - 999 MI or km. Display appears as: RANGE: XXX MILES (English), RANGE: XXX km (Metric). If the range is less than 40 miles, RANGE: LOW will be displayed. AVERAGE FUEL ECONOMY The Average Fuel Economy (AFE) value is calculated by the cluster based on Trip Distance and Trip Fuel Used. Pressing the Select button for longer than 3 seconds while the Average Fuel Economy is displayed in the DIC will reset both the Trip Distance and Trip Fuel Used to 0.0. Average Fuel Economy is capable of displaying values from 0.0 to 99.9. Display appears as: AVG MPG XX.X (English), AVG L/100km XX.X XX (Metric), AVG km/l XX.X (Japanese). Trip Distance and Trip Fuel Used accumulated values are stored in memory when the ignition is turned OFF. INSTANTANEOUS FUEL ECONOMY Instantaneous Fuel Economy values are calculated by the cluster from odometer information and class 2 messages. The cluster calculates instantaneous fuel economy based on distance and fuel. Instantaneous fuel economy is capable of displaying values from 0.0 to 99.9. Display appears as INST MPG XX.X (English), INST L/100km XX.X (Metric), INST km/l XX.X (Japanese). Values for the Instantaneous fuel economy are not stored when the ignition is turned OFF. ENGINE OIL LIFE Engine Oil Life percentage values are based on class 2 messages to the IPC. The IPC requests this value when Engine Oil Life is selected on the DIC. Engine Oil Life is capable of displaying values from 0 to 100%. Pressing the Select button for longer than 5 seconds while Engine Oil Life is displayed on the DIC the value will reset to 100%. Display appears as ENGINE OIL LIFE: XXX%. FEATURE PROGRAMMING Refer to Personalization Description and Operation. DRIVER WARNINGS Page 2933 Abbreviations And Meanings Part 5 Page 666 Memory Seat Module - Passenger C2 Page 11985 For vehicles repaired under warranty use, the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty use, the table. Page 3417 NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 1. Install the exhaust manifold heat shield with the 4 nuts. Tighten the exhaust manifold heat shield nuts to 10 Nm (89 inch lbs.). 2. Install the oxygen sensor. 3. Install the oil level indicator. 4. Move the transmission filler tube back onto the stud and secure the tube with the nut. Tighten the transmission filler tube bracket nut to 10 Nm (89 inch lbs.). 5. Install the air cleaner resonator outlet duct. Page 2890 Page 4752 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Instrument Panel Air Register: Service and Repair Instrument Panel AIR OUTLET REPLACEMENT - INSTRUMENT PANEL REMOVAL PROCEDURE 1. Using a flat-bladed tool, release the left housing retaining pin and gently push the left side of the air outlet into the housing assembly. 2. With the air outlet in the housing assembly, rotate the air outlet face down. 3. Using a flat bladed tool, remove the left side of the air outlet from the housing assembly. 4. Remove the air outlet from the housing assembly. INSTALLATION PROCEDURE Page 4961 For vehicles repaired under warranty, use the table. Disclaimer Locations Engine, Left Side Page 8887 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. - Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. - Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. - Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Page 2034 Hose/Line HVAC: Service and Repair Evaporator Drain Hose EVAPORATOR DRAIN HOSE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the HVAC module-auxiliary. 2. Remove the HVAC module pass through seal (3) from the HVAC module-auxiliary (1). 3. Remove the evaporator drain hose-auxiliary (2) from the HVAC module-auxiliary (1). INSTALLATION PROCEDURE 1. Install the evaporator drain hose-auxiliary (2) to the HVAC module-auxiliary (1). 2. Install the HVAC module pass through seal (3) to the HVAC module-auxiliary (1). 3. Install the HVAC module-auxiliary. Page 7258 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 12657 4. Install the overhead console to the roof. Page 13104 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 3133 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 422 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Specifications Oil Level Sensor: Specifications Oil Level Sensor Bolt 89 inch lbs. Page 13117 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 4138 Abbreviations And Meanings Part 24 Page 4603 Fuel Injector 2 Page 4079 Page 869 Abbreviations And Meanings Part 14 Page 9743 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 13018 Abbreviations And Meanings Part 19 Application and ID Relay Box: Application and ID Location View Application Table Part 1 Page 12987 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 8889 ^ Visually inspect the steering shaft for sheared injected plastic. If the steering shaft shows sheared plastic, replace the steering shaft. ^ Any frame damage that could cause a bent steering shaft must have the steering shaft runout checked. Using a dial indicator (1) at the lower end of the steering shaft, rotate the steering wheel. The runout must not exceed 1.60 mm (0.06 inch). Page 5922 Disclaimer Page 13181 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Access IP module connector through glove box. 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 4514 1. Connect the crankcase clean air hose to the air cleaner outlet resonator (2). 2. Connect the crankcase clean air hose to the valve cover port. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the 2 resonator to engine bolts (4) to the air cleaner outlet resonator (5). Tighten the bolts to 6 Nm (63 lb in). Specifications Oil Pressure Sensor: Specifications Oil Pressure Sensor 15 ft. lbs. Page 3282 Heater Control Valve: Service and Repair COOLANT BYPASS VALVE REPLACEMENT TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 2. Remove the coolant recovery reservoir. 3. Using the J 43181, disconnect the inlet heater hose from the heater core. 3.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 3.2. Close the tool around the inlet heater core hose. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 4. Position the hose clamp at the engine outlet using J 38185. 5. Remove the heater inlet hose (4) from the engine block. 6. Remove the nut retaining the coolant bypass valve to the cowl. 7. Remove the vacuum hose from the coolant bypass valve. 8. Remove the coolant bypass valve. 9. Position the clamps at the coolant bypass valve. 10. Remove the heater inlet hoses form the coolant bypass valve. INSTALLATION PROCEDURE Page 7333 Fuse Block - Rear C2 Part 2 Page 9441 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Wheels/Tires - Recommended Wheel Nut Torque Wheel Fastener: All Technical Service Bulletins Wheels/Tires - Recommended Wheel Nut Torque File In Section: 03 Suspension Bulletin No.: 02-03-10-008 Date: December, 2002 INFORMATION Subject: Recommended Wheel Nut/Bolt Torque Specifications Models: 2003 Passenger Cars and Light Duty Trucks 2003 HUMMER H1, H2 This bulletin is being issued to list the recommended wheel nut/bolt torque specifications for passenger cars and light duty trucks for the 2003 model year. Disclaimer LF Page 10188 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 1771 Window Switch - RR Part 1 Page 3691 Accelerator Pedal Position (APP) Sensor Page 9684 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 5424 Disclaimer Recall - Spark Plug Misfire Condition Spark Plug: Recalls Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Page 13527 8. If replacing the dome lamp bulb (1), remove the dome lamp bulb from the socket. INSTALLATION PROCEDURE 1. If replacing the dome lamp bulb (1), install the dome lamp bulb to the socket. 2. If replacing the reading lamp bulb (1), install the reading lamp bulb to the socket. 3. Install the reflector (2) to the dome lamp, ensuring the retaining tabs are fully seated. Page 12985 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 7187 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 4121 Abbreviations And Meanings Part 7 Page 9532 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 8286 Ambient Air Temperature Sensor Page 10180 Page 59 Abbreviations And Meanings Part 4 Page 1720 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 13729 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Open the left instrument panel (IP) access cover. 2. Reach into the access hole and release the 4 retaining tabs located on the headlamp switch behind the IP. 3. Remove the headlamp switch from the IP, through the IP access hole. 4. Disconnect the electrical connectors from the headlamp switch. 5. Remove the headlamp from the IP. INSTALLATION PROCEDURE Page 10351 Abbreviations And Meanings Part 4 Page 4456 Park/Neutral Position Switch (C2) Page 6963 Fuse Block - Rear C4 Part 2 Page 10843 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 503 7. Install the protective cover (1) to the module. 8. Position the right second row seat to a passenger position. 9. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 10. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 11. Use the ID information menu on the scan tool to access the new station ID (STID) and the electronic serial number (ESN) from the new VCIM. 12. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center and perform the following procedure: 12.1. Tell the advisor that this vehicle has received a new VCIM. 12.2. Ask the advisor to add the new STID and the ESN to update the customer's account. 12.3. Follow any additional instructions from the OnStar(R) advisor. 12.4. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. Body - Rattle from Front of Vehicle Hood Latch: Customer Interest Body - Rattle from Front of Vehicle Bulletin No.: 03-08-63-003 Date: December 04, 2003 TECHNICAL Subject: Rattle From Front of Vehicle (Adjust Hood Latch Following New Procedure) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada Condition Some customers may comment on a rattle coming from the front of their vehicle. Cause The hood latch may have been improperly adjusted. Correction Adjust the hood latch following the procedure below. 1. Open the hood and insert the prop rod. 2. Remove the grille. Refer to Grille Replacement in SI. 3. Remove the left and right adjustable rubber bumpers. 4. Return the prop rod to its secured position and close the hood in a normal manner, engaging the primary latch. 5. Loosen all three hood latch bolts. 6. Inspect the left and right side hood fit to the fender. Assure that the hood is at a minimum of 2 mm (0.078 in) below the fenders on both sides. Apply downward pressure to the center of the hood above the latch in order to gain the 2 mm (0.078 in). 7. With downward pressure to the center of the hood, tighten the latch bolts. Refer to illustration above. Tighten Tighten the latch bolts to 10 N.m (89 lb in). Page 8040 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Page 12493 Page 3445 Page 12967 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9923 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 1544 Electronic Frontal Sensor - Right Page 10613 Page 6765 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. A/C - Intermittently Inoperative/Poor Performance Control Module HVAC: All Technical Service Bulletins A/C - Intermittently Inoperative/Poor Performance Bulletin No.: 02-01-39-005A Date: August 17, 2005 TECHNICAL Subject: HVAC System Inoperative For A Drive Cycle, Poor HVAC System Performance In High Ambient Temperatures (Update HVAC Control Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to correct the RPO usage information below: RPO CJ2 = HVAC System Air Conditioner Front, Automatic Temperature Control, Auxiliary Temperature Control RPO CJ3 = HVAC System Air Conditioner Front, Manual Temperature Control, Auxiliary Temperature Control Please discard Corporate Bulletin Number 02-01-39-005 (Section 01 - HVAC). Condition Some customers may comment about no cold air from the heating, ventilation and air conditioning (HVAC) system during a drive cycle. This concern may occur at any time during the drive cycle and at any temperature setting. The HVAC system operation returns to normal after the vehicle has been keyed to off and restarted. This concern is intermittent and most likely to occur on hot days. This concern may be found on vehicles equipped with manual (CJ3) and automatic (CJ2) HVAC systems. Other customers may comment about poor HVAC system performance in high ambient temperature conditions. This concern may be present in automatic (CJ2) HVAC systems only. An HVAC control module software update was put into all production vehicles beginning in September 2002. Vehicles built in September 2002 and earlier may need this software update. Correction Update the HVAC control module using software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. This software update addresses both the intermittent no cooling and the poor performance concerns. If the software update does not correct the concerns, perform the HVAC Diagnostic System Check and repair as necessary. If the HVAC control module is replaced with a part from GMSPO, make sure the module has the latest software update. The module may need to be updated even though it is a new part. Warranty Information Disclaimer Locations Wiper Switch: Locations Windshield Wiper Switch Page 5840 3. Install the axle shaft seal using the J21128. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover and the gasket. 7. Install the tire and wheel assembly. 8. Fill the rear axle with axle lubricant. Use the proper fluid. 9. Lower the vehicle. Page 3891 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the protective cover from the underhood fuse block. 2. Remove the compressor relay (1) from the underhood fuse block (2). INSTALLATION PROCEDURE 1. Install the compressor relay (1) to the underhood fuse block (2). 2. Install the protective hood to the underhood fuse block. Page 8342 Page 13606 Hazard Warning Flasher: Diagrams Turn Signal/Hazard Flasher Module Part 1 Specifications Ride Height Sensor: Specifications Air Spring Leveling Sensor to Frame Mounting Bolts 7 ft. lbs. A/C - Musty Odors On Start Up Control Module HVAC: All Technical Service Bulletins A/C - Musty Odors On Start Up Bulletin No.: 05-01-39-002A Date: March 17, 2006 TECHNICAL Subject: Musty Odor from HVAC System (Reprogram HVAC Control Module to Enable Afterblow Function) Models: 2004-2006 Buick Rainier 2003-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2003-2004 Oldsmobile Bravada with Automatic Temperature Control HVAC System (RPO CJ2) Supercede: This bulletin is being revised to add the 2006 model year and update the calibration release date. Please discard Corporate Bulletin Number 05-01-39-002 (Section 01 - HVAC). Condition Some customers may comment on a musty odor from the Heating, Ventilation and Air Conditioning (HVAC) system. This condition occurs most often on initial start up after the vehicle was driven on a hot humid day. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. Correction Important: The afterblow function should not be enabled until after the purpose and operation of it is explained to your customer and they approve of the change. Once the afterblow function is enabled there are no calibrations currently released to disable it. Technicians are to reprogram the HVAC Control Module with an updated software calibration that will enable the afterblow function. The new calibration will be released beginning with TIS satellite data update version 2.0, which was made available February 5, 2006. The blower motor will turn on approximately 10 minutes after the vehicle is shut off. The blower motor will run continuously for 10 minutes at a 30% duty cycle. The afterblow function will only activate if the air conditioning compressor was engaged during conditions of high ambient temperature. If the vehicle is started within 10 minutes of the last key off, the afterblow function from the previous key cycle will be cancelled. Technicians should not attempt to reprogram a vehicle with a Manual Temperature Control HVAC system (RPO CJ3). Technicians should perform this HVAC Control Module reprogram instead of installing the Electronic Evaporator Dryer Module Kit referred to in the Air Conditioning Odor bulletin, Corporate Bulletin Number 99-01-39-004A. Warranty Information Page 6342 9. Install the brake caliper assembly. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Caution: Refer to Firm Brake Pedal Caution in Service Precautions. Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury. 12. Pump the brake pedal slowly and firmly in order to seat the brake pads. Rear Brake Caliper Bracket Replacement- Rear Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Inspect the brake caliper assembly. Notice: Support the brake caliper with heavy mechanics wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 4. Remove the rear brake caliper assembly, relocate the brake caliper to the side. 5. Inspect the brake pads. Page 12177 Abbreviations And Meanings Part 22 A/C - Poor Rear Heater Performance Auxiliary Water Pump: All Technical Service Bulletins A/C - Poor Rear Heater Performance Bulletin No.: 05-01-37-002A Date: November 01, 2005 TECHNICAL Subject: Poor Rear Heat Performance (Install Auxiliary Heater Pump) Models: 2003-2005 Chevrolet TrailBlazer EXT 2003-2005 GMC Envoy XL Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 05-01-37-002 (Section 01 - HVAC). Important: Implementation of this Service Bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on poor 2nd and/or 3rd row seating heater performance when the vehicle is at idle. Cause This condition may be due to lack of coolant circulation to the rear heater core. Correction Install auxiliary heater pump package, P/N 89024885 (L6 Engine RPO LL8) or P/N 89024886 (V8 Engine RPO LM4 or LH6). This pump will improve coolant flow to the rear heater core. Use the procedure listed below. 1. Recover the A/C refrigerant. 2. Drain the cooling system. 3. Disconnect the negative battery cable. 4. Remove the fender rear upper brace. 5. Remove the air cleaner cover. 6. Remove the air cleaner filter element and air outlet duct. 7. Remove the air inlet duct from the lower air cleaner housing/washer solvent tank assembly. 8. Disconnect the washer solvent tank electrical and remove wiring harness from the retaining clips. 9. Disconnect the washer pump hoses and plug the pump outlet ports to prevent loss of washer solvent. 10. Remove the two air cleaner housing/washer tank assembly retaining nuts from the mounting studs. 11. Lift the lower air cleaner housing/washer tank assembly off of the studs and remove the assembly. 12. On the A/C accumulator, disconnect the electrical connector from the low pressure switch. 13. Remove the compressor suction hose assembly from the accumulator. 14. Remove the nut retaining the accumulator to the evaporator. 15. Remove the coolant hoses from the coolant recovery reservoir. Page 965 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Fuel Hose/Pipes Replacement - Filter to Engine Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Filter to Engine REMOVAL PROCEDURE CAUTION: Refer to Fuel and EVAP Pipe Caution in Service Precautions. - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the powertrain control module connectors from the powertrain control module (PCM). 3. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail. NOTE: Refer to Fuel and Evaporative Emission (EVAP) Hose/Pipe Connection Cleaning Notice in Service Precautions. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Disconnect the EVAP purge pipe (5) from the EVAP canister purge valve. 6. Disconnect the integral clip (3) from the engine bracket. 7. Remove the EVAP/fuel hose/pipe assembly from the fuel pipe clip at the rear of the engine. 8. Remove the fuel tank shield, if equipped. 9. Use the following procedure with two wheel drive (2WD): 9.1. Remove the EVAP/fuel hose/pipe assembly retaining bolt (3) from the transmission. 9.2. Disengage the EVAP/fuel hose/pipe assembly from the clip at the rear of the transmission. 10. Use the following procedure with four wheel drive (4WD): Page 12181 Abbreviations And Meanings Part 26 Page 7507 C901 Page 2198 Fuse: Application and ID Fuse Block - Rear (Long Wheelbase) Location View Page 13132 Abbreviations And Meanings Part 4 Page 10670 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 6695 Abbreviations And Meanings Part 17 Page 3486 Abbreviations And Meanings Part 3 Page 657 Power Seat Control Module: Diagrams Memory Seat Module - Driver C1 Page 1702 Page 13783 Turn Signal/Multifunction Swtich C4 Page 11524 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield. 3. Remove the evaporative emission (EVAP) canister from its mounting bracket. Do not disconnect the canister lines. 4. Support the transmission with a transmission jack. 5. Remove the transmission mount to the transmission support retaining nuts. 6. Remove the lower transmission support to the frame mounting bolts. 7. Remove the upper transmission support to the frame mounting bolts. 8. Remove the transmission support from the frame. Installation Procedure Page 11123 Important: Punch the center of the weld so that as much of the weld as possible is removed during drilling. 5. Center punch each weld location (1). Important: Drill through the hinge base only (1). Do not drill through the mating surface (2). 6. Remove the hinge tab (3) before drilling, if necessary. 7. At each punch location, drill a 3 mm (1/8 in) pilot hole (1). 8. Using the pilot hole as a guide, drill through the hinge base using a 19 mm (3/4 in) rotabroach hole saw or equivalent (2). Important: If necessary, use a chisel to separate the hinge from the mating surface. 9. Remove the hinge. Page 10308 Page 5176 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 13918 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 8398 Abbreviations And Meanings Part 18 Page 3462 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 7690 11. Remove the CPA from the RF side impact module yellow 2-way connector (1) located under the passenger seat. 12. Disconnect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 13. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 14. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 9 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 13412 Page 5573 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Steering - Moan/Groan Shudder on Low Speed Turns Steering Gear: Customer Interest Steering - Moan/Groan Shudder on Low Speed Turns Bulletin No.: 04-02-32-007A Date: December 01, 2004 TECHNICAL Subject: Steering System Moan, Groan, Shudder and/or Vibration Type Noise During Low Speed Turning Maneuvers (Replace Steering Gear) Models: 2004-2005 Buick Rainier 2003-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2003-2004 Oldsmobile Bravada Short Wheelbase Utilities Built Prior to VIN Breakpoint 52123375 Long Wheelbase Utilities Built Prior to VIN Breakpoint 56137280 Supercede: This bulletin is being revised to remove the 2002 model year and add the long wheelbase utilities. Please discard Corporate Bulletin Number 04-02-32-007 (Section 02 - Steering). Condition Some customers may comment on a moan, groan, shudder and/or vibration noise while making low speed turning maneuvers. Customers usually notice this condition in parking lot turning maneuvers. Correction 1. Diagnose the power steering concern. Refer to Symptoms - Power Steering System. 2. Replace the steering gear with a newly designed steering gear. See the parts information below. Refer to Power Steering Gear Replacement. Parts Information Parts are currently available from GMSPO. Warranty Information Body - Liftgate Glass Hard to Close Trunk / Liftgate Handle: Customer Interest Body - Liftgate Glass Hard to Close File In Section: 08 - Body and Accessories Bulletin No.: 03-08-66-006 Date: June, 2003 TECHNICAL Subject: Lift Gate Glass Hard to Close (Replace Weatherstrip and Shim Handle) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the lift gate glass is hard to close. Cause The weatherstrip may be too stiff and the glass bounces back when closing. Correction Replace the weatherstrip and shim the lift gate window handle. 1. Remove the garnish molding from the lift gate for easy access to the weatherstrip. 2. Remove the lift gate weatherstrip. 3. Install the lift gate glass weatherstrip. 4. Install the garnish molding. 5. Loosen the two nuts that retain the handle and the striker to the glass and install the shim between the glass and the striker. Tighten Tighten the nuts to 6 N.m (53 lb in). Important: Page 8567 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12113 Lighting - Turn Signal Flasher Sticks ON Turn Signal Flasher: All Technical Service Bulletins Lighting - Turn Signal Flasher Sticks ON Bulletin No.: 03-08-42-014 Date: December 09, 2003 INFORMATION Subject: New Turn Signal Flasher Module Availability Models: 2004 Buick Rainier 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet SSR - Built Prior to VIN Breakpoint 3B101657 2003-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2003-2004 Oldsmobile Bravada Built After April 2003 New Flasher Module Availability Important: Always use the part number listed in the table below for flasher replacement on the above vehicles. The factory installed Turn Signal Flasher Module in the vehicles listed above has been superseded by a revised part number. Do not use the original flasher module part number if a replacement is needed. An anomaly has been observed in the original production flasher that could cause the flasher module to stick in the "on" position if the directional signal is used for an extended period of time. Always use the part number listed in the table below for flasher replacement on the above vehicles. Parts Information Parts are currently available from GMSPO. Disclaimer Page 327 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 8548 Control Module HVAC: Service and Repair Control Module HVAC - Auxiliary Auxiliary Heater and Air Conditioning Control Module Replacement Removal Procedure 1. Using a flat bladed tool, carefully pry out on the top of the HVAC control-auxiliary. 2. Remove the HVAC control-auxiliary from the center console/seat. 3. Disconnect the electrical connector. 4 remove the HVAC control-auxiliary. Installation Procedure Page 1397 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Page 2037 Hose/Line HVAC: Service and Repair HVAC Pipe Straight Line Repair HEATER AND AIR CONDITIONING (A/C) PIPE REPLACEMENT/REPAIR - AUXILIARY TOOLS REQUIRED J 41425 A/C Line Repair Kit Do not service the rear A/C or heater lines as a complete unit. Service the rear A/C or heater lines as a sectional repair. You can obtain the various sections of line through GMSPO. Use the J 41425 when any of the following actions damage the rear A/C or heater lines: - Rub-through - Collision damage - Leakage in the system Minimum Tube Length Required Table IMPORTANT:When sectioning the rear A/C or heater lines, ensure that the correct minimum length remains in the straight part of the line on both sides of the splice. Follow the Straight Line Repair procedure in order to repair line damage in a straight section of line. Follow the Line Sectioning Repair procedure in order to repair any damage in a bend area. Do not repair the rear A/C or heater lines in a bend area, replace the lines. Maintaining the original line shape will prevent vibrations and rub-through. Straight Line Repair 1. Recover the refrigerant, if repairing the A/C lines. 2. Drain the coolant, if repairing the heater lines. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Locate the area that requires repair. 5. Obtain a length of replacement line to make the repair. 6. Use a tubing cutter in order to cut and remove the section of damaged line. 7. Use a tubing cutter in order to cut the replacement line to length. Page 12548 Abbreviations And Meanings Part 16 Page 7502 C600 Part 2 C700 Part 1 Body - Liftgate Glass Binds/Won't Open Fully Center Mounted Brake Lamp: Customer Interest Body - Liftgate Glass Binds/Won't Open Fully Bulletin No.: 04-08-66-017 Date: November 09, 2004 TECHNICAL Subject: Liftgate or Liftgate Glass Binds, Does Not Open Completely, CHMSL Hits Roof (Remove Material from CHMSL Applique) Models: 2002-2005 Chevrolet TrailBlazer EXT 2002-2005 GMC Envoy XL Condition Some customers may comment that the liftgate or liftgate glass binds when opening or does not open all the way. Cause This condition is caused by the Center High Mounted Stop Lamp (CHMSL) applique hitting the roof of the vehicle. Correction Verify that the CHMSL applique is not loose or broken off one or more of its mounting points. If the applique is broken, it will be necessary to order a replacement part. Important: ^ It should not be necessary to replace the liftgate glass. ^ All measurements and alterations should take place prior to paint finish. ^ It is necessary to install any replacement parts in order to measure to determine if further modification is required. To achieve the proper clearance, modification to the applique is required using the following procedure: 1. Measure (with applique installed) the area of interference in order to determine the material to be removed. ^ The top surface (height) of the applique should line up approximately 1 mm (0.039 in) below the top surface of the roof. ^ A gap of 6-8 mm (0.236-0.315 in) should exist between the roof and the applique to allow for adequate clearance while opening the liftgate. Page 5973 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 860 Abbreviations And Meanings Part 5 Instruments - Erratic Speedometer Operation Speedometer Head: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 4037 Powertrain Control Module (PCM) C1 Part 4 Page 4975 Torque Converter Clutch Solenoid: Diagrams Torque Converter Clutch Pulse Width Modulated (TGC PWM) Solenoid Valve Connector, Wiring Harness Side Torque Converter Clutch (TCC) Solenoid Valve Connector, Wiring Harness Side Page 3927 Abbreviations And Meanings Part 14 Page 8091 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 13388 Ambient Light Sensor (With RPO Code CJ3) Page 7190 For vehicles repaired under warranty, use the table. Disclaimer Page 10906 Body Control Module (BCM) C3 Part 4 Page 7574 Disclaimer Page 5890 prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. 2. Assemble 1 bearing cup part way into 1 side of the yoke. Turn the yoke ear toward the bottom. 3. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. 4. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 5. Install the opposite bearing cup part way into the yoke ear. 6. Ensure that the trunnions start straight and true into both bearing cups. 7. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 8. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. Page 10398 Theft Deterrent Control Module Page 7834 Control Arm: Specifications Rear Axle Lower Control Arm Mounting Bolts 74 ft. lbs. Locations Door Switch: Locations Door Jamb Switch, Miniwedge - LR Page 12036 WA8624/50 - WA882K/90 Page 4036 Powertrain Control Module (PCM) C1 Part 3 Page 6876 Conversion - English/Metric Part 1 Page 1511 47. Connect the electrical connector to the A/C low pressure switch. 48. Install the lower air cleaner housing/washer solvent tank assembly onto the mounting studs. 49. Install the two air cleaner housing/washer tank assembly retaining nuts to the mounting studs. 50. Connect the washer pump hoses. 51. Connect the washer solvent tank electrical and install wiring harness to the retaining clips. 52. Install the air inlet duct to the lower air cleaner housing/washer solvent tank assembly. 53. Install the air cleaner filter element and air outlet duct. 54. Install the air cleaner cover. 55. Install the tender rear upper brace. 56. Connect the negative battery cable. 57. Recharge the refrigerant system. 58. Fill the cooling system. 59. Inspect the cooling system for leaks. 60. Leak test the refrigerant fittings using J 39400-A. Parts Information Warranty Information Page 5779 Wiring Harness: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 Shift control solenoid (2) ^ 2-3 Shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Page 12371 Passenger Seat Lumbar Actuators, Driver Seat Similar Page 6489 12. Remove the park brake retaining bracket bolt from the frame. 13. Remove the park brake retainer from the frame, left rear shown. 14. Depress the retaining clips for the parking brake cable. 15. Remove the park brake from the mounting bracket. 16. Remove the park brake cable from the actuator. 17. Push the park brake cable through the frame toward the inside from the vehicle. 18. Remove the park brake cables from the vehicle. Installation Procedure Page 9864 IMPORTANT: - The adhesion promoter must be used to assure adequate bonding of the coupling. - Mask or protect the surrounding area before applying the adhesion promoter. Remove the protective film from the adhesive backing on the inner antenna coupling. IMPORTANT: Ensure the inner and outer antenna couplings are aligned. - Do not touch the adhesive backing on the antenna coupling. 1. If the exterior antenna coupling is not installed, use a grease pencil on the outside glass to mark the mounting location of the interior antenna coupling. Ensure the marks are level. 2. The mounting location for the couplings is on the left quarter window, 100 mm (4 in) (A) rearward of the black masking (1), and 48 mm (2 in) (B) below the black masking. 3. If the exterior antenna coupling is installed, align the inner antenna coupling to the exterior coupling. 4. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the back glass (4). Hold pressure on the inner coupling (2) for 10-30 seconds. 5. Inspect the installation to ensure that no surface gaps are present between the couplings (5,2) and the back glass (4). Page 13121 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 7688 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 6. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. 5. Access the I/P module connector through the glove box. Page 4086 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 2888 Page 9821 Abbreviations And Meanings Part 13 Page 6336 Locations Body Control Module: Locations Body Wiring Harness Extension Harness Page 876 Abbreviations And Meanings Part 21 Page 13002 Abbreviations And Meanings Part 3 Page 7117 C316 Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 9524 OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 1222 Ambient Temperature Sensor / Switch HVAC: Diagrams Air Temperature Sensor-Lower Left Page 560 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 875 Abbreviations And Meanings Part 20 Page 4105 Conversion - English/Metric Part 1 Page 8515 Control Assembly: Description and Operation HVAC System - Automatic HVAC SYSTEM - AUTOMATIC AIR DELIVERY HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings.The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal.The control module supports the features as in the table. AIR TEMPERATURE HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings.The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal.The control module supports the features as in the table. Page 13406 Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by November 30, 2005. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement~ they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Note: Page 8245 2. Disconnect the electrical connector from the defroster actuator. 3. Remove the screws from the defroster actuator. 4. Remove the defroster actuator. INSTALLATION PROCEDURE 1. Install the defroster actuator. 2. Install the defroster actuator screws. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector to the defroster actuator. 4. Install the IP carrier. Mode Actuator MODE ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P carrier. Page 12358 Memory Seat Module - Driver C4 Part 1 Page 349 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 7260 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 14020 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 6363 Page 10503 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 13113 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 10708 4. Remove the electrical connectors from the VCIM. 5. Remove the VCIM from the vehicle INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. 2. Install the module to the upper bracket ensuring the retaining tab is fully seated. 3. Connect the 2 electrical connectors. NOTE: In order to avoid damage to the circuit board, do NOT over-tighten the thumb screws. Using your fingers, apply only a light pressure. Tighten Tighten the module thumb screw to a maximum of 0.2 N.m (2 lb in). Page 410 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 6459 Brake Master Cylinder: Service and Repair Master Cylinder Overhaul MASTER CYLINDER OVERHAUL Disassembly Procedure 1. Remove the brake master cylinder from the vehicle. Refer to Master Cylinder Replacement. 2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 4. Remove the reservoir cap and diaphragm from the reservoir. 5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are present, replace the affected components. ^ Cuts or cracks ^ Nicks or deformation Page 11948 11. Install the three torque head screws. Tighten Tighten the torque head screws to 10 Nm (89 lb-in.). 12. Install the wire harness if equipped with heated mirror and turn signal. 13. Line up the mirror back with the actuator. Press firmly in the center of the glass using the palm of your hand. The mirror and backing plate will snap onto the actuator. 14. Make sure the mirror is locked in by lightly pulling on the mirror glass. Check the operation of the mirror and clean the glass. Parts Information Parts are expected to be available from GMSPO on September 24, 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12852 Registered And Non-Registered Trademarks Part 3 Page 25 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 8651 IMPORTANT:The length of the replacement line must be the same as the section being replaced. 8. Use the cleaning pad from the J 41425 in order to clean any burrs or grease from the line ends. Be sure to clean at least 19 mm (0.75 in) from the line splice area. 9. Use the LOK prep sealant in order to prep the line ends. 10. Apply one drop of the J 41425-3 sealing compound to the outside of each end of the line. 11. Insert the line ends into the LOK fitting. 12. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 13. Install the correct LOK fitting jaws into the J 41425-1 tool. 14. Install the J 41425-1 tool over the LOK connectors.Verify that the LOK connector ends are positioned in the counter bores of the jaws. 15. Tighten the forcing screw of the J 41425-1 tool.When fully seated, the LOK connector collars will bottom out on the center shoulder of the LOK fitting. IMPORTANT:Hold the J 41425-1 tool body with a 3/8" breaker bar. 16. Loosen the forcing screw and remove the J 41425-1 tool from the repaired line. 17. Repeat Step 8 through Step 16 to complete the line splice. 18. Verify that the LOK fittings are correctly installed. 19. Lower the vehicle. 20. Refill the coolant, if drained. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 21. Evacuate and recharge the refrigerant, if repairing the A/C lines. Line Sectioning Repair HEATER AND AIR CONDITIONING (A/C) PIPE REPLACEMENT/REPAIR - AUXILIARY TOOLS REQUIRED J 41425 A/C Line Repair Kit Do not service the rear A/C or heater lines as a complete unit. Service the rear A/C or heater lines as a sectional repair. You can obtain the various sections of line through GMSPO. Use the J 41425 when any of the following actions damage the rear A/C or heater lines: - Rub-through - Collision damage - Leakage in the system Page 1825 Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Locations Power Seat Page 6682 Abbreviations And Meanings Part 4 Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 6993 Application Table Part 2 Page 7337 Fuse Block - Rear C2 Part 6 Page 7988 4. Install J24319-B to the shock module yoke to lower control arm stud. 5. Disconnect the shock module yoke from the lower control arm using J24319-B. 6. Remove the shock module yoke to shock absorber pinch bolt and nut. 7. Spread the shock module yoke at the pinch belt using a flat bladed tool. 8. Remove the shock module yoke from the shock absorber. Installation Procedure Page 12168 Abbreviations And Meanings Part 13 Page 2054 Removal Procedure 1. Drain the engine coolant. 2. Reposition the inlet radiator hose clamp (2) at the radiator using J 38185. 3. Remove the inlet radiator hose from the radiator. 4. Reposition the inlet radiator hose clamp (1) at the engine outlet using J 38185. 5. Remove the inlet radiator hose from the engine. Installation Procedure 1. Install the inlet radiator hose clamps (1, 2) to the radiator hose. 2. Install the inlet radiator hose to the engine. 3. Reposition the inlet radiator hose clamp (1) using J 38185. 4. Install the inlet radiator hose to the radiator. 5. Reposition the inlet radiator hose clamp (2) using J 38185. 6. Fill the cooling system. Page 9398 Registered And Non-Registered Trademarks Part 6 Page 12002 Disclaimer Page 4731 Tighten the clamps to 2.5 N.m (22 lb in). 17. Lower the vehicle. 18. Install the fuel fill pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the fuel fill pipe housing. 20. Install the fuel fill cap. Parts Information Parts are expected to be available from GMSPO on August 13, 2004. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 7676 Power Steering Pump: Service and Repair Power Steering Pump Bracket Replacement Power Steering Pump Bracket Replacement Removal Procedure 1. Remove the power steering pump. 2. Remove the drive belt tensioner. 3. Remove the power steering pump bracket mounting bolts. 4. Remove the power steering pump bracket. Installation Procedure 1. Install the power steering pump bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the power steering pump bracket mounting bolts. Tighten the power steering pump mounting bolts to 50 Nm (37 ft. lbs.). 3. Install the drive belt tensioner. 4. Install the power steering pump. OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure ^ Remove the drive belt. Refer to Drive Belt Replacement. ^ Remove the 3 power steering pump bolts and move the pump out of the way. ^ Disconnect the camshaft position actuator solenoid electrical connector. ^ Remove the camshaft position actuator solenoid retaining bolt (3). ^ Remove the camshaft position actuator solenoid (2) from the engine block. ^ Clean debris from the hole (1). Installation Procedure ^ Lubricate the hole (1) with engine oil. Notice: Refer to Fastener Notice in the Preface section. Page 2720 8. Install the oil level indicator. 9. Remove the oil level indicator and check the oil level. Add oil if necessary. Check for any oil leaks. Page 1379 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE 1. Install the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Page 4278 Abbreviations And Meanings Part 12 Page 9007 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module yellow 4-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 1. Remove the key from the ignition. Page 13255 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 1509 40.5. Route the other end of the harness along the rear of the engine compartment to the left side and secure to the cross bar and dash panel with tie straps. Locations Steering Column Page 6609 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12 volt positive, negative ground electrical system. Do not try to jump start a vehicle if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed. Leave the hazard flashers ON. 2.5. Turn OFF the ignition switch. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: 8.1. Turn the ignition OFF. 8.2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. 8.3. Attempt to start the engine of the vehicle with the discharged battery. 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump Page 4319 7. Install the rear electrical center cover. 8. If replacing the BCM on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 9. If replacing the BCM on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 10. Connect the negative battery cable. 11. If installing a replacement BCM, program the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Body Wiring Harness Extension Replacement - BCM BODY WIRING HARNESS EXTENSION REPLACEMENT - BCM REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the body wiring harness extension on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the body wiring harness extension on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. Page 11826 Abbreviations And Meanings Part 11 Page 3500 Abbreviations And Meanings Part 17 Page 9346 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 12805 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Locations Cruise Control Switch (Multifunction Switch) Page 7925 Ride Height Sensor: Service and Repair Air Spring Leveling Sensor Replacement Removal Procedure Important: Remove the air suspension system fuse before working on the rear suspension components or the rear axle. Failure to remove the air suspension system fuse could cause the calibration of the air suspension leveling sensor to change and the air suspension system not to function properly. 1. Remove the air suspension system fuse. 2. Ensure that the vehicle is parked on level surface. 3. Inspect tires for proper tire pressure. 4. Inspect the air suspension system components for damage or defects. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Remove the rear tire and wheels. 7. Support the rear axle and set the rear axle to proper D height. 8. Disconnect the air spring level sensor link from the upper control arm. 9. Disconnect the air spring level sensor electrical connector. Page 11604 Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Position the carpet to the floor panel. 2. Raise the rear portion of the floor console bracket and slide the carpet underneath the console bracket. 3. Position the rear carpet over the edge of the front carpet. 4. Align the holes in the carpet to the seat studs on the floor panel. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the four nuts retaining the rear of the floor console bracket to the floor weld studs. Tighten the nuts to 25 N.m (18 lb ft). 6. Feed the bussed electrical center base and the communication interface module electrical connectors through the pass through holes in the carpet. 7. Install the floor console. 8. Install the child restraint tether anchors. 9. Install the bussed electrical center. 10. Install the tool kit carrier. 11. Install the 3 tool carrier nuts to the floor studs. Tighten the nuts to 7 N.m (62 lb in). 12. Install the lower rear quarter trim panels. 13. Install the center pillar trim panels. 14. Install the lift gate door sill plate. 15. Install the rear door sill plates. 16. Install the front door sill plates. 17. Install the front bucket seats. 18. Instal the seat back, right and left side. 19. Install the navigation control processor bracket to the floor panel. 20. Install the rear seat cushions. 21. Install the communication interface module. 22. Install the front seats. Page 13784 Windshield Wiper/Washer Switch (Turn Signal/Multifunction Switch C3) Page 8310 40.6. Install the ring terminal (orange wire) to the underhood fuse block stud (1). 40.7. Locate circuit no. 241 or 441 (ignition 3 brown wire) (PIN B11 or C11) in the existing underhood fuse block harness (1) of C2 (2) and splice bare wire to it using a splice clip. Wrap with electrical tape. 40.8. Locate connector C105 (3), located on the left side inner fender. Separate the connector halves. On the female side of the connector, remove the terminal from cavity F (gray/black wire) and tape back. 40.9. Install the terminal end on the pump wiring harness into cavity F of connector C105. 41. Install the evaporator tube and nut to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 42. Install the coolant recovery reservoir with the accumulator attached. 43. Install the nut and bolt securing the coolant recovery reservoir. 44. Install the coolant hoses to the coolant recovery reservoir. 45. Install the nut retaining the accumulator to the evaporator. Tighten Tighten the nut to 28 N.m (21 lb ft). 46. Install the compressor suction hose assembly to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). Page 358 Parts Information Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: Customer Interest Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 13944 Abbreviations And Meanings Part 14 Page 12883 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 6977 Fuse Block - Underhood C3 Part 2 Page 3139 Compression Check: Testing and Inspection Engine Compression Test Tools Required J 38722 Compression Tester A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. Important: The battery must be at or near full charge. 1. Remove the air duct from the throttle control module. 2. Remove the ignition control modules. 3. Disable the fuel system. 4. Remove the spark clues. 5. Measure the engine compression, using the following procedure: 5.1. Firmly install J 38722 to the spark plug hole. 5.2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 5.3. Check and record the readings on J 38722 at each stroke. 5.4. Disconnect J 38722. 5.5. Repeat the compression test for each cylinder. 6. Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. 7. The following are examples of the possible measurements: - When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. - When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. - When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. - When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 8. Install the air duct to the throttle body. 9. Install the spark plugs. 10. Enable the fuel system. 11. Install the ignition control modules. Page 8408 Registered And Non-Registered Trademarks Part 2 Lubricant Level Inspection - Rear Drive Axle Fluid - Differential: Service and Repair Lubricant Level Inspection - Rear Drive Axle Lubricant Level Inspection - Rear Drive Axle 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. Specification The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. Page 3878 Procedures Power Seat Switch: Procedures Lumbar Switch Replacement - Front LUMBAR SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the switch bezel assembly from the seat. 2. Remove the power seat switch. 3. Release the tabs that retain the lumbar switch to the switch bezel assembly. 4. Disconnect the electrical connector from the lumbar switch. 5. Remove the lumbar switch from the switch bezel assembly. INSTALLATION PROCEDURE 1. Connect the electrical connector to the lumbar switch. 2. Install the lumbar switch to the switch bezel assembly, verifying that the retaining tabs are fully seated. 3. Install the power seat switch. 4. Install the switch bezel assembly to the seat. Seat Switch Bezel Replacement SEAT SWITCH BEZEL REPLACEMENT REMOVAL PROCEDURE Page 8863 Low Pressure Sensor / Switch: Diagrams A/C Low Pressure Switch (w/Manual - HVAC System) Page 3966 7. Install the rear electrical center cover. 8. If replacing the BCM on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 9. If replacing the BCM on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 10. Connect the negative battery cable. 11. If installing a replacement BCM, program the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Body Wiring Harness Extension Replacement - BCM BODY WIRING HARNESS EXTENSION REPLACEMENT - BCM REMOVAL PROCEDURE IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the body control module (BCM). - Always disconnect the 40-way body wiring extension FIRST, the 32-way tan connector SECOND and the 24-way gray electrical connector LAST. - Always connect the 24-way gray electrical connector FIRST, the 32-way tan connector SECOND and the 40-way body wiring extension LAST. - The BCM can set DTCs with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection cannot detect shorts on inputs or other circuits which the BCM does not control. Use the scan tool in order to activate the POWER DOWN NOW mode. Use the POWER DOWN NOW mode in order to check for current draws on circuits that are not controlled by the BCM, or controlled by the battery run down protection system. - Do not touch the exposed electrical contacts of the body wiring extension. 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. If replacing the body wiring harness extension on a Chevrolet TrailBlazer EXT or GMC Envoy XL, remove the left second row seat. 3. If replacing the body wiring harness extension on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a cargo position. 4. Remove the rear electrical center cover. Page 1554 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 2 and SIR Disabling and Enabling Zone 6. CAUTION: Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the front door trim panel. 3. Peel the rear half of the water deflector away from the door in order to access the side impact sensor. 4. Remove the screws that retain the side impact sensor (2) to the door. 5. Disconnect the impact sensor electrical connector (1) from the side impact sensor. 6. Remove the side impact sensor from the door. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Position the side impact sensor (2) horizontally to the door. 3. Connect the electrical connector (1) to the side impact sensor (2). 4. Install the screws which retain the side impact sensor to the door. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Page 13902 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: Customer Interest OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 9196 Registered And Non-Registered Trademarks Part 3 Page 1712 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 12136 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 10034 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 8952 Tighten the screws to 8 N.m (71 lb in). 5. Fully seat the water deflector to the door. 6. Install the door trim panel. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 2 and SIR Disabling and Enabling Zone 6. Page 10191 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 2823 Abbreviations And Meanings Part 21 Page 8212 Air Temperature Actuator-Right Page 2039 Minimum Tube Length Required Table IMPORTANT:When sectioning the rear A/C or heater lines, ensure that the correct minimum length remains in the straight part of the line on both sides of the splice. Follow the Straight Line Repair procedure in order to repair line damage in a straight section of line. Follow the Line Sectioning Repair procedure in order to repair any damage in a bend area. Do not repair the rear A/C or heater lines in a bend area, replace the lines. Maintaining the original line shape will prevent vibrations and rub-through. Line Sectioning Repair 1. Recover the refrigerant, if repairing the A/C lines. 2. Drain the coolant, if repairing the heater lines. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Obtain a new A/C or heater line for sectioning. 5. Scribe a mark on the line that will be sectioned. IMPORTANT:Stagger the splices if repairing more than one line. 6. Use a tubing cutter in order to cut the line or lines being replaced. 7. Remove the section of line being replaced from the vehicle. 8. Install the replacement line to the vehicle. IMPORTANT:The length of the replacement line must be the same as the line being replaced. 9. Use a tubing cutter in order to cut the replacement line to length. 10. Use the cleaning pad from the J 41425 in order to clean any burrs or grease. Be sure to clean at least 19 mm (0.75 in) from the line splice area. 11. Use the LOK prep sealant in order to prep the line ends. 12. Apply one drop of the J 41425-3 sealing compound to the outside of each line end. 13. Insert the line ends into the LOK fitting. 14. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines. 15. Install the correct LOK fitting jaws into the J 41425-1 tool. 16. Install the J 41425-1 tool over the LOK connectors.Verify that the LOK connector ends are positioned in the counter bores of the jaws. 17. Hold the tool body with a 3/8" breaker bar. Turn the forcing screw until both of the connector collars bottom on the center shoulder of the LOK fitting. 18. Loosen the forcing screw. Remove the tool from the repaired line. 19. Verify that the LOK fitting is correctly installed. 20. Lower the vehicle. 21. Refill the coolant, if drained. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 22. Evacuate and recharge the refrigerant, if repairing the A/C lines. Page 1344 Headlamp Switch C1 Part 2 Page 9076 Seat Belt Retractor: Service and Repair No. 2 Right Rear REMOVAL PROCEDURE 1. Remove the rear seat belt upper guide shoulder bolt. 2. Remove the right rear quarter trim panel. 3. Remove the rear seat belt lower anchor nut. 4. Remove the bolt that retains the seat belt retractor assembly to the body. 5. Remove the seat belt retractor assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt retractor assembly to the vehicle. 2. Install the seat belt retractor assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat belt retractor bolts to 70 N.m (52 lb ft). 3. Install the right rear quarter trim panel. 4. Install the rear seat belt lower anchor nut. Ensure that the seat belt webbing is not twisted. Tighten Tighten the rear seat mounting nut to 45 N.m (33 lb ft). 5. Install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten Page 9628 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. General Overview Page 265 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 6466 Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the master cylinder bolts and nuts Tighten the nuts to 36 N.m (27 lb ft). 6. Remove the rubber plugs from the brake lines 7. Connect the brake pipes to the master cylinder. Tighten the pipe nuts to 30 N.m (22 lb ft). 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding. A/T, Exhaust - Rattling Noise From Under the Vehicle Transmission Cooler: Customer Interest A/T, Exhaust - Rattling Noise From Under the Vehicle Bulletin No.: 04-07-30-002 Date: January 20, 2004 TECHNICAL Subject: Rattle Type Noise Coming From Under the Vehicle (Reposition Transmission Oil Cooler Lines) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on a rattle type noise coming from under the vehicle. Cause This condition may be caused by one of the transmission oil cooler lines contacting the exhaust catalytic converter. Correction Raise the vehicle and carefully reposition the transmission oil cooler line(s) to provide 10 mm (0.393 in) clearance between the exhaust catalytic converter and the line. Replace the transmission oil cooler line if any damage is present. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4305 Body Control Module (BCM) C3 Part 1 Page 10213 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 12570 Seat Heater: Electrical Diagrams Heated Seats Diagram Page 6207 Abbreviations And Meanings Part 6 Page 9723 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 4836 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 9097 Inflatable Restraint Side Impact Sensor-Right (SISM) Page 2286 12. Disconnect the body wiring harness connector (1) from the junction block. 13. Disconnect the headliner harness connector (2) from the junction block. 14. Disconnect the console harness connector from the junction block. 15. Remove the block base retaining nuts from the floor studs. 16. Remove the block base from the floor panel. INSTALLATION PROCEDURE 1. Install the block base to the floor studs. 2. Install the block base retaining nuts to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the block base retaining nuts to 10 N.m (88 lb in). 3. Connect the console harness connector to the block base. 4. Connect the headliner harness connector (2) to the block base. 5. Connect the body wiring harness connector (1) to the block base. Page 565 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Page 11706 Trim Panel: Service and Repair Garnish Molding Replacement - Body Side Window - Rear (TrailBlazer EXT, Envoy XL) Garnish Molding Replacement - Body Side Window - Rear (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the bolt that retains the seat belt upper anchor to the body. 2. Remove the garnish molding from the vehicle. Installation Procedure 1. Install the garnish molding to the vehicle. 2. Install the seat belt retractor to the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt that retains the seat belt anchor to the body. Tighten the anchor bolt to 70 N.m (52 lb ft). Locations Body Front End Page 12866 Electronic Brake Control Module (EBCM) C1 Page 2980 2. Install the valve spring and the valve spring retainer. 3. Use the J 44228 and compress the valve springs. 4. Install the valve keys. 5. Remove the J 44228. Page 9210 Steps 1-6 Page 11122 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door - Door Side Hinge Replacement - Rear Door - Door Side Removal Procedure The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all. 1. Remove all of the related panels and components. 2. Remove the sealer surrounding the hinge (1). 3. Scribe the location of the hinge (1). 4. Hand-sand the existing hinge (1) with 100-grit sandpaper to locate the 4 weld locations. Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 5400 The second design oil pump rotor (212) and slide (203) are identified with dimples (circular depression) as shown above. The rotor (212) has two dimples adjacent to the rotor drive tangs (1). The slide (203) has one dimple located on the spring tab (2). Disclaimer Page 10158 Page 6868 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 9320 Page 2271 6. Connect the mobile telephone harness connector (1) to the junction block. 7. Connect the instrument panel harness connector (1) to the block base. 8. Install the junction block to the block base. Ensure that the retaining tabs are fully seated. Page 12184 Registered And Non-Registered Trademarks Part 3 Page 10796 6. Remove the steering wheel control switch from the steering wheel. Installation Procedure 1. Position the steering wheel control switch to the steering wheel. 2. Connect the electrical connector to the steering wheel control switch. 3. Install the steering wheel control switch into the steering wheel, ensuring the retaining tabs are fully seated. 4. Install the shroud to the steering wheel. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the shroud retaining screws to the steering wheel. Tighten the screws to 2 Nm (18 inch lbs.). 6. Install the steering wheel. Page 3581 Powertrain Control Module (PCM) C2 Part 2 Page 10502 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 7999 Installation Procedure 1. Install the splash shield to the steering knuckle. Align the splash shield to the steering knuckle threaded holes. 2. Install the wheel hub and bearing to the steering knuckle. Align the threaded holes. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel hub and bearing to the steering knuckle mounting bolts. Tighten the wheel hub and bearing mounting bolts to 105 Nm (77 ft. lbs.). 4. Install the ABS sensor to the wheel hub and bearing. 5. Install the ABS sensor mounting bolt to the wheel hub and bearing. Tighten the ABS sensor to the wheel hub and bearing mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the brake rotor. 7. Install the tire and wheel. Page 7550 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 2548 ^ Drill Motor with 1/2 inch chuck, 11/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction. Note: Please ensure that the cylinder bore sleeve trim tool has been updated with the new trimmer pilot. The old trimmer pilot, black in color for identification, may cause damage to the tool or to the sleeve. An updated trimmer pilot (EN-45680-499) was sent in November, 2004 to affected Chevrolet and GMC dealers. The new pilot is white in color, and should be installed on EN-45680-411 Trim Tool Assembly. Buick and HUMMER dealers were sent EN-45680-400 Cylinder Liner Replacer kit with the correct pilot already installed. Inspect EN-45680-411 to ensure the correct white pilot is installed. Page 1444 NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). 4. Lower the vehicle. Page 11997 Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. Page 297 For vehicles repaired under warranty use, the table. Disclaimer Page 6306 Notice: Whenever the rotor has been separated from the axle flange, clean any rust or foreign material from the mating surface of the axle flange and brake rotor. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. Important: If the brake rotor is not going to be replaced but just removed from the front hub to be refinished, mark the brake rotor left or right and relationship of the brake rotor and a wheel stud. In doing so, is will reduce the possibility of vibration in the brake system. 9. Remove the brake rotor. 10. Using the J 42450-A, clean the brake rotor to rear axle flange contact area. 11. Refinish the rotor if necessary. Installation Procedure 1. Clean the park brake shoes using denatured alcohol. 2. Dry the park shoes using non-lubricated, filtered air. 3. Lubricate the contact area between the park brake shoe and the backing plate with high temperature silicone brake lubricant. Page 2396 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 7403 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9201 Accessory Delay Module: Electrical Diagrams Retained Accessory Power (RAP) Diagram Page 6662 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 10654 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 12203 Door Control Module Diagram 3 Keyless Entry - System Inoperative Door Module: Customer Interest Keyless Entry - System Inoperative Bulletin No.: 03-08-52-002 Date: March 27, 2003 TECHNICAL Subject: Remote Keyless Entry Inoperative (Reprogram Liftgate Module) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Condition Some customers may comment that the Remote Keyless Entry (RKE) is inoperative at times. Cause An anomaly has been identified with the software in the Liftgate Module (RKE functions). The Liftgate Module software is affected when the temperature is approximately 40°C (104°F). Correction Using normal SPS reprogramming procedures, reprogram the LGM Liftgate module. The information was released on TIS version 2.75 or newer broadcast in March 2003. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9789 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 8900 6. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 7. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 8. Disconnect the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 9. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 10. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Page 13031 Registered And Non-Registered Trademarks Part 6 Page 6277 1. Install the brake pad retaining clips on the brake caliper mounting bracket. 2. Install the brake pads to the brake caliper mounting bracket. Important: Ensure that the retaining clip for the brake pads is properly seated in the brake caliper. 3. Install the retaining clip from the brake caliper. Page 12287 Sunroof / Moonroof Motor: Description and Operation SUNROOF MOTOR The sunroof has a bi-directional motor. When the sunroof motor is not operating both control circuits are grounded. When the sunroof motor drives the sunroof glass in the direction from the vent position to the open position, the following occurs: Voltage is supplied to the sunroof motor open control circuit. - Ground is maintained to the sunroof motor close control circuit. When the motor drives the sunroof glass in the direction from the open position to the vent position, the following occurs: Voltage is supplied to the sunroof motor close control circuit. - Ground is maintained to the sunroof motor open control circuit. The sunroof motor understands when it has driven the sunroof glass to the vent, close and full open positions based on the internal limit switches within the sunroof control module. The sunroof control module interprets the limit switch combinations and controls the sunroof motor to soft stop the sunroof glass at the positions. The sunroof control module is equipped with a timer circuit which stops the operation of the sunroof motor after 8 seconds. Page 9170 Abbreviations And Meanings Part 3 A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: All Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Page 9322 Page 9563 Service and Repair Pinion Gear: Service and Repair Drive Pinion and Ring Gear Replacement Tools Required ^ J8614-01 Flange and Pulley Holding Tool ^ J22536 Pinion Driver ^ J38694 Extension Housing Oil Pump/Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake calipers. 4. Remove the brake rotors. 5. Remove the axle shafts. 6. Remove the differential assembly. 7. Remove the drive pinion yoke and the oil seal. 8. Install the J22536 as shown. Ensure that the J22536 is firmly seated on the pinion. 9. Drive the pinion out using the J22536 and a hammer. Strike the J22536 slowly. Do not let the pinion fall out of the rear axle housing. 10. Remove the collapsible spacer from the pinion. Discard the spacer. 11. Remove the pinion bearings and the cups. 12. Remove the left-hand threaded ring gear bolts. Discard the bolts. 13. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Installation Procedure Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Page 952 Engine Control Module: Diagrams Powertrain Control Module (PCM) C3 Powertrain Control Module (PCM) C3 Part 1 Page 2910 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Description and Operation Air Cleaner Restriction Indicator: Description and Operation The air cleaner restriction indicator is located on the intake duct between the air cleaner assembly and the throttle body. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Page 13 Page 9357 Conversion - English/Metric Part 1 Page 10905 Body Control Module (BCM) C3 Part 3 Page 13593 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9137 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 10882 Abbreviations And Meanings Part 18 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 3466 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 13192 6. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 7. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 8. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 9. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. 10. Install the SIR fuse to the fuse block (1) located in the underhood electrical center. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition. Page 11849 Door Module: Connector Views Driver Door Module (DDM) - C1 Page 1586 Disclaimer Page 9259 Global Positioning System Antenna: Service and Repair Coupling Replacement - Antenna Outer COUPLING REPLACEMENT - ANTENNA OUTER REMOVAL PROCEDURE 1. Install the inner coupling first, if both the inner and outer couplings are to be replaced. IMPORTANT: The adhesion promoter must be used to assure adequate bonding of the coupling. - To obtain maximum adhesion between the new cellular antenna couplings and the glass surface, the cellular antenna couplings and the glass must be kept dry and above 15°C (60°F) during the installation, and for 24 hours immediately following the installation. Otherwise the new couplings may not remain on the glass. - Do not attempt to reinstall the original couplings using any type of glue, adhesive tapes, etc. Doing so, may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Use a thin, wide-bladed plastic tool to cut the double back tape material, while lifting up on the outer antenna coupling. INSTALLATION PROCEDURE 1. Clean the outside of the back glass with alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. 3. Apply Glass Adhesion Promoter GM P/N 12378555 (Canadian P/N 88901239) to the back glass in the area the antenna coupling is to be installed. Follow the Glass Adhesion Promoter instructions on the product label. IMPORTANT: The adhesion promoter must be used to assure adequate bonding of the coupling. - Mask or protect the surrounding area before applying the adhesion promoter. Remove the protective film from the adhesive backing on the outer antenna coupling. Page 11113 Rear Door Exterior Handle: Service and Repair Door Handle Replacement - Rear Outside (TrailBlazer, Envoy, Bravada) Door Handle Replacement - Rear Outside (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Release the clip that retains the lock rod to the handle. 4. Remove the lock rod from the handle. 5. Remove the nut that retains the handle and bracket to the door. 6. Remove the bracket from the handle. 7. Remove the handle from the door. Installation Procedure 1. Install the handle to the door. 2. Install the bracket to the handle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nut that retains the handle to the bracket. Tighten the nut to 10 N.m (88 lb in). 4. Install the lock rod to the handle. 5. Install the clip that retains the lock rod to the handle. 6. Install the water deflector. 7. Install the door trim panel. LF Page 10430 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 13099 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 12971 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 6065 Electronic Components Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 6872 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 10184 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Service and Repair Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Tools Required - J 38820 Valve Stem Seal Remover and Installer - J 44222 Camshaft Sprocket Holding Tool - J 44228 Valve Spring Compressor Removal Procedure Important: Organize the valve train components when disassembling so they can be reassembled in the same location and matched up with the same components, as previously installed. 1. Remove the cam cover. 2. Remove the spark plugs. 3. Remove the exhaust and the intake sprocket bolts. 4. Install the J 44222 onto the cylinder head in order to keep from disturbing the timing chain components. 5. Adjust the 2 horizontal bolts into the camshaft sprockets to maintain chain tension. 6. Carefully move the sprockets with the timing chain, off of the camshafts. 7. Remove the camshaft cap bolts. Important: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed. 8. Remove the camshaft caps. Page 6979 Fuse Block - Underhood C4 Part 1 Page 46 Conversion - English/Metric Part 1 A/C - Musty Odors On Start Up Control Module HVAC: Customer Interest A/C - Musty Odors On Start Up Bulletin No.: 05-01-39-002A Date: March 17, 2006 TECHNICAL Subject: Musty Odor from HVAC System (Reprogram HVAC Control Module to Enable Afterblow Function) Models: 2004-2006 Buick Rainier 2003-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2003-2004 Oldsmobile Bravada with Automatic Temperature Control HVAC System (RPO CJ2) Supercede: This bulletin is being revised to add the 2006 model year and update the calibration release date. Please discard Corporate Bulletin Number 05-01-39-002 (Section 01 - HVAC). Condition Some customers may comment on a musty odor from the Heating, Ventilation and Air Conditioning (HVAC) system. This condition occurs most often on initial start up after the vehicle was driven on a hot humid day. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. Correction Important: The afterblow function should not be enabled until after the purpose and operation of it is explained to your customer and they approve of the change. Once the afterblow function is enabled there are no calibrations currently released to disable it. Technicians are to reprogram the HVAC Control Module with an updated software calibration that will enable the afterblow function. The new calibration will be released beginning with TIS satellite data update version 2.0, which was made available February 5, 2006. The blower motor will turn on approximately 10 minutes after the vehicle is shut off. The blower motor will run continuously for 10 minutes at a 30% duty cycle. The afterblow function will only activate if the air conditioning compressor was engaged during conditions of high ambient temperature. If the vehicle is started within 10 minutes of the last key off, the afterblow function from the previous key cycle will be cancelled. Technicians should not attempt to reprogram a vehicle with a Manual Temperature Control HVAC system (RPO CJ3). Technicians should perform this HVAC Control Module reprogram instead of installing the Electronic Evaporator Dryer Module Kit referred to in the Air Conditioning Odor bulletin, Corporate Bulletin Number 99-01-39-004A. Warranty Information Frame Brace Replacement (Trailblazer EXT, Envoy XL) Structural Brace: Service and Repair Frame Brace Replacement (Trailblazer EXT, Envoy XL) Frame Brace Replacement (Trailblazer EXT, Envoy XL) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the mounting bolts (2) from the frame brace (1). 3. Remove the frame brace (1) from the frame. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the frame brace (1) to the frame using the mounting bolts (2). OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 1621 Park/Neutral Position Switch (C2) Page 1805 Wiper Switch: Diagrams Rear Window Wiper/Washer Switch Page 7097 C303 (With RPO Code Z70) Page 12044 Page 1965 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Drive Belt Falls Off Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. The drive belt may have been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Page 182 Disclaimer Page 3942 Registered And Non-Registered Trademarks Part 3 Page 1799 Windshield Wiper/Washer Switch (Turn Signal/Multifunction Switch C3) Page 1351 1. Install the horn switch (2) to the steering wheel (3). Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the horn contact plate (2) captured screws (1, 4) to the steering wheel (3). Tighten the screws to 5.5 Nm (50 inch lbs.). 3. Install the horn plunger to the steering column. 4. Install the inflator module. 5. Enable the SIR system. Page 5439 For vehicles repaired under warranty, use the table. Disclaimer Page 8236 3. Disconnect the electrical connector from the mode actuator. 4. Remove the screws from the mode actuator (1). 5. Remove the mode actuator. Installation Procedure Page 9753 5. Remove the rear retaining bolt. 6. Carefully remove the bracket from the vehicle through the headliner opening. INSTALLATION PROCEDURE 1. Carefully install the bracket to the vehicle through the headliner opening, ensuring the locating tabs (1) are fully seated to the roof bow. 2. Partially install the front bracket retaining bolts. 3. Carefully pull down on the rearward edge of the headliner in order to expose the rear bolt installation area. 4. Partially install the rear bracket retaining bolt. 5. Fully seat the retaining bolts. Page 9350 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 7322 Application Table Part 4 Location View Page 11665 Headliner: Service and Repair Headliner Replacement (TrailBlazer, Envoy, Bravada) Headliner Replacement (TrailBlazer, Envoy, Bravada) Caution: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure to do so could result in personal injury. Removal Procedure 1. Ensure the ignition switch is in the LOCK position. 2. Remove the cargo net, if equipped. 3. Remove the luggage/cargo shelf assembly, if equipped. 4. Remove the right sound insulator panel. 5. Remove the front door sill plates. 6. Remove the rear door sill plates. Notice: Remove the headliner and the headliner harness as an assembly. Do NOT cut or splice the headliner harness. Cutting or splicing the harness may damage the coax cable, resulting in poor radio performance. 7. Remove the center pillar trim panels. 8. Remove the windshield garnish moldings. 9. Remove the video display. 10. If equipped, remove the front and rear overhead console. Refer to Overhead Console Replacement - Front, or to Overhead Console Replacement Rear. 11. Remove the sunshades from the headliner. 12. If equipped with OnStar(R), perform the following procedure: 1. Disconnect the navigation antenna cable from the communication interface module. 2. Remove the navigation antenna cable from the right side door rocker panel attachments. 3. Remove the navigation antenna cable from the right center pillar. 13. Remove the following headliner harness clips from the left center pillar: * The center pillar harness clips (4) * The center pillar harness clips (3) * The center pillar harness clips (1) 14. Remove the center pillar harness ground bolt (2). 15. Remove the harness from the left center pillar. Page 6118 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: Thoroughly wash all contaminants from around the EHCU. The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 1. Disconnect the two electrical harness connectors from the EBCM (2). Important: Make sure that brake lines are tagged and kept in order for proper reassembly. 2. Disconnect the 5 brake lines from the BPMV (3). 3. Remove 2 bolts (4) securing the BPMV mounting bracket (5) to the BPMV (3). 4. Disconnect the 2 way ABS pump motor connector. 5. Remove the four T-25 TORX screws (1) from the EBCM (2). Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 7. Clean the EBCM (2) to BPMV (3) mounting surfaces with a clean cloth. Installation Procedure Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Page 11125 Notice: Refer to Fastener Notice in Service Precautions. 7. Align the hinge (1) and the backing plate (2) with the holes in the door (3). 8. Hand tighten all of the 4 supplied bolts (4). 9. Align the hinge. Tighten the 4 bolts to 25 N.m (18 ft lb). 10. Clean and prepare all bare-metal surfaces. 11. Apply a full-bodied caulk around the service hinge. 12. Refinish as necessary. 13. Install and align all of the related panels and components. Page 4255 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Page 9511 Circuit/System Testing Component Testing Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 9520 Page 11863 Door Control Module Diagram 3 Page 4616 Steps 5-7 Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Read this procedure carefully and completely. 2. The BCM will not function properly if the Setup New BCM procedure is not performed. 3. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 6400 Disclaimer Service Procedure Tools Required (for brake pipe replacement, if required) J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent J 35589-A Brake Pressure Bleeder Adapter The following procedure provides instruction for inspecting, and if necessary, replacing the brake pipe located between the left front brake caliper flex hose and the ABS modulator. Inspection Procedure 1. Place the vehicle on a suitable hoist and turn the steering wheel to the full right. 2. Open the hood. 3. Raise and support the vehicle. 4. Clean and remove any dirt from the left front brake pipe and flare nut (3) where it connects to the left front caliper flex hose (4). 5. Carefully inspect the brake pipe where it goes into the flare nut for a tooling mark (1) as shown above. The mark may be located at any point around the circumference of the pipe and a mirror and flashlight may be required to see it. There will NOT be any of the spiral lines or grooves (2) in the tooling mark. ^ If the tooling mark IS present (1), then the brake pipe does NOT need to be replaced. Lower the vehicle and install the GM Recall Identification Label. Page 1112 Position Sensor - Recline Motor (w/Memory) Page 4581 9. Pour the fuel sample from the beaker (1) into the J 44175, until the level of the fuel is at the top of each fuel test port (2). IMPORTANT: DO NOT allow any substances other than gasoline, ethanol/gasoline blends, air, or acetone into the test ports of the fuel composition tester. Contaminants in the J 44175 could result in misdiagnosis. 10. Observe the diagnostic LEDs on the fuel composition tester. If the red fuel diagnostic LED is illuminated, a fuel contamination condition exists. Refer to Fuel System Cleaning. 11. Measure the output frequency of the fuel composition tester. Fuel Composition Test Examples 12. Subtract 50 from the reading on the DMM to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the table. 13. If the fuel sample contains more than 10 percent ethanol, add gasoline to the fuel tank or replace the fuel in the vehicle. Page 9359 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 6551 Electronic Brake Control Module: Specifications EBCM to BPMV 39 inch lbs. Page 603 Abbreviations And Meanings Part 15 Page 12841 Abbreviations And Meanings Part 18 Page 136 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 9542 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 1656 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 1968 Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Drive Belt Excessive Wear Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Page 9897 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 6514 Page 5380 7. Remove the transmission jack. 8. Install the clip (2) that holds the cooler lines together. 9. Install the cooler lines to the retainer (1) located on the right side of the engine. 10. Install the front sections of the cooler lines to the vehicle. 11. Install the cooler lines to the retainer (1) located on the radiator shroud. 12. Connect the front and rear cooler lines at the quick connect fitting (2). 13. Install the transmission cooler lines to the radiator. 14. Remove the drain pan from under the vehicle. 15. Lower the vehicle. 16. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Diagrams Heater Control Valve: Diagrams Coolant Bypass Valve (Body Type VIN 6) (w/Manual - HVAC System) Page 5221 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Specifications Drive Belt Tensioner: Specifications Drive Belt Tensioner Bolt 37 ft. lbs. Page 2550 4. Ensure that the metal shaving catch plug EN 45680-413 is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. Important: Before using trim tool assembly EN 45680-411 the height of the cutting blades must be set to the proper specification. The proper specification is that the cylinder bore sleeve flange must be flush to +0.02 mm (0.0008 in) above the block deck surface. 5. The groove side of the set gage ring EN 45680-412 (1) should be positioned upward on a flat surface. Important: Ensure that the set gage ring EN 45680-412 surfaces are clean. 6. Carefully position trim tool assembly EN 45680-411 onto the set gage ring EN 45680-412. 7. Loosen the shaft collar screw (2). 8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3). Page 9219 1. Install the antenna mast to the antenna base. NOTE: Use tape on the tool surface so that you do not damage the paint on the antenna mast. 2. Screw the antenna mast to the antenna base. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the antenna mast to 5 N.m (44 lb in). Page 10064 Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 4349 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 8399 Abbreviations And Meanings Part 19 Page 9169 Abbreviations And Meanings Part 2 Page 97 Steps 7-12 Page 9716 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Page 4250 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 12794 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 4364 Powertrain Control Module (PCM) C3 Part 2 Page 1290 Door Switch: Diagrams Miniwedge (Door Jamb Switch) - LF Front Lower Control Arm Control Arm: Specifications Lower Control Arm Bracket Front Mounting Bolt 192 ft.lbs. Lower Control Arm Bracket Front Mounting Bolt 192 ft. lbs. Lower Control Arm Bracket Rear Mounting Bolt 177 ft. lbs. Lower Control Arm to the Lower Control Arm Bracket Mounting Nuts 81 ft. lbs. Page 6812 Abbreviations And Meanings Part 16 Page 10321 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 7006 8. Release the tabs that retain the junction block to the block base. 9. Remove the junction block from the block base. 10. Disconnect the instrument panel harness connector (1) from the junction block. 11. Disconnect the mobile telephone harness connector (1) from the junction block. Page 4175 - U1300 - U1301 - U1305 6. A state of health DTC with a history status may be present along with a U1000 or U1255 code having a current status. This indicates that the malfunction occurred when the ignition was ON. 7. Data link connector terminals 2 and 5 provide the connection to the class 2 serial data circuit and the signal ground circuit respectively. 10. A poor connection at DLC terminal of the splice pack SP205 would cause this condition but will not set a DTC. 11. An open in the class 2 serial data circuit between the DLC and splice pack SP205 will prevent the scan tool from communicating with any module. This condition will not set a DTC. 12. The class 2 serial data circuit is shorted to voltage or ground. The condition may be due to the wiring or due to a malfunction in one of the modules. When testing the wire for a short, make sure there is not a module connected to the wire being tested. This test isolates the BCM and the PCM class 2 serial data circuits. 13. This test isolates the BCM class 2 serial data circuits. 16. The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must remain connected to the DLC for any other module to communicate with the scan tool. This test isolates the splice pack SP306 serial data circuits. 21. This test isolates the rest of the splice pack SP205 serial data circuits. 25. If there are no current DTCs that begin with a "U", the communication malfunction has been repaired. 26. The communication malfunction may have prevented diagnosis of the customer complaint. Scan Tool Does Not Power Up SCAN TOOL DOES NOT POWER UP CIRCUIT DESCRIPTION The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16. - Scan tool power ground at terminal 4. - Common signal ground at terminal 5. The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. TEST DESCRIPTION Knock Sensor (KS) 1 Front Knock Sensor (KS) 1 Front Service and Repair Carrier Bearings: Service and Repair Differential Side Bearings Replacement Tools Required ^ J8092 Universal Driver Handle- 3/4 inch - 10 ^ J21784 Side Bearing Installer ^ J22888-D Side Bearing Puller Kit ^ J45231 Differential Side Bearing Installer Removal Procedure 1. Remove the differential. 2. Remove the differential side bearings by performing the following steps: 2.1. Install the differential assembly in a vise. 2.2. Install the J22888-20A (2) and the J8107-2, 8.0 inch axle, or the J8107-4, 8.6 inch axle (1), as shown. 2.3. Remove the differential side bearings using the J22888-20A. 3. Remove the differential assembly from the vise. Installation Procedure 1. Install the differential side bearings by doing the following: 1.1. In order to protect the differential case, install the J8107-2, 8.0 inch axle, or the J8107-4, 8.6 inch axle, in the case on the side opposite the bearing installation. 1.2. Install the J45231, 8.0 inch axle, or the J21784, 8.6 inch axle (2), and the J8092 (1) onto the differential case bearing as shown. 1.3. Drive the bearing onto the case using the J45231, 8.0 inch axle, or the J21784, 8.6 inch axle (2) and the J8092 (1). 2. Install the differential. Page 10508 Circuit/System Testing Component Testing Page 7232 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 6500 1. Install the park brake lever assembly to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the right front park brake lever retaining nut. ^ Tighten the park brake lever mounting nut to 25 Nm (18 ft. lbs.). 3. Connect the electrical connector to the park brake warning lamp switch. 4. Raise the vehicle. 5. Connect the park brake cables to the equalizer. 6. Lower the vehicle. 7. Install the floor console. 8. Enable the park brake automatic adjuster. Page 14023 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 12037 WA882K/90 - WA900J/59 Page 2755 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 9174 Abbreviations And Meanings Part 7 Electrical - Proper Jump Starting Procedure Jump Starting: Technical Service Bulletins Electrical - Proper Jump Starting Procedure Bulletin No.: 04-06-03-005A Date: May 17, 2006 INFORMATION Subject: Proper Connection Information to Avoid Blown 125 Amp Fuse and Various Interior Electrical System Conditions When Jump Starting Vehicle Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2007 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-06-03-005 (Section 06 - Engine/Propulsion System). It has been found that some dealers may be using the IP battery positive stud at the underhood fuse block to jump start the vehicle. This bulletin is being issued to inform dealers that investigation has indicated the 125 amp mega fuse (no. 48) located in the engine compartment fuse block may be blown resulting in various electrical system conditions due to using this improper connection. To properly jump start the vehicle, you must always use the following connections. For the positive connection, use the battery terminal. For the negative connection, use the remote terminal located on the front engine lift bracket (marked "GND"). Page 12463 1. Install the seat cushion panel on the pad and cover. 2. Install the J-strips (2) securing the seat cushion cover to the seat cushion panel. 3. Install the pull handle (1). 4. Install the rear seat cushion assembly (1) to the seat latch rod (3) with two rear seat cushion bolts (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat cushion bolts to 11 N.m (97 lb in). Page 861 Abbreviations And Meanings Part 6 Page 9525 Page 613 Abbreviations And Meanings Part 25 Page 2909 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 6644 Page 9254 Global Positioning System Antenna: Description and Operation CELLULAR AND NAVIGATION ANTENNAS This vehicle will be equipped with either separate cellular and navigation antennas, or a combination cellular and navigation antenna, which brings the functions of both into a single part. The cellular antenna is the component that allows the OnStar(R) system to send and receive data over airwaves by means of cellular technology. This antenna is connected at the base to a coax cable that plugs directly into the VCIM. The navigation antenna is used to collect the constant signals of the orbiting satellites. Within the antenna, is housed a low noise amplifier that allows for a more broad and precise reception of this data. Current GPS location is collected by the module every time a keypress is made. The OnStar(R) Call Center also has the capability of pinging the vehicle during an OnStar(R) call, which commands the module to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged. In the event the VCP loses or is removed from power, this history location is used by the OnStar(R) Call Center as a default. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. This antenna requires a clear and unobstructed path to the satellites in the sky. Window tinting on vehicles may interfere with the GPS sensor functions, depending upon the amount of darkening and/or metallic particles that are embedded in the film of the tinting material. Page 13111 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 4094 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Specifications Piston Pin: Specifications Piston & Pin Piston Diameter - (1.4961 inch) down from top 3.6627-3.6633 inch Piston to Bore Clearance 0.0004-0.0017 inch Piston to Pin Clearance 0.00012-0.0005 inch Pin Bore 0.9056-0.9058 inch Piston Pin Diameter 0.9054-0.9055 inch Page 1962 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Drive Belt Chirping Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive Page 7489 C311 Page 1449 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. OnStar(R) - Module Cover Retaining Tab Breaking Emergency Contact Module: Customer Interest OnStar(R) - Module Cover Retaining Tab Breaking Bulletin No.: 02-08-46-008A Date: January 16, 2008 INFORMATION Subject: OnStar(R) Module Cover Retaining Tab Breaking Models: 2002-2003 Chevrolet and GMC S/T Utility Models (TrailBlazer Envoy) 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to add an Important statement. Please discard Corporate Bulletin Number 02-08-46-008 (Section 08 - Body & Accessories). This repair can ONLY be performed if the OnStar(R) System has been upgraded to Digital. Please refer to Corporate Bulletin Number 05-08-46-006N (or later) - Information on Upgrading Certain OnStar Analog/Digital-Ready Systems to OnStar Generation 6 Digital capable System. The OnStar(R) module located under the passenger side rear seat has a protective cover. If the module requires service the retaining clips of the cover may become damaged when the cover is removed or reinstalled. When reinstalling the cover it is suggested the following procedure be used. Position the cover in the correct position over the OnStar(R) module and bracket assembly. Using a 3.57 mm (9/64 in) drill bit drill a hole for a retaining screw in the two front corners of the cover flange and the bracket assembly. Install a self-tapping screw into the holes just drilled. The suggested screw is P/N 11516629. This is a black Phillips head screw with washer head (4.1 X 1.4 X 16). Tighten the screw until fully driven seated and not stripped. Parts Information Warranty Information For vehicles repaired under warranty use the table. Disclaimer A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2830 Registered And Non-Registered Trademarks Part 2 Page 1681 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 2717 IMPORTANT:When adding to, or changing the engine oil, use ONLY oils of the proper quality. In countries other than the United States and Canada, it may be difficult to find engine oils that display the API STARBURST symbol certifying the oil is for use in gasoline engines. If you are unable to find engine oils displaying the API STARBURST symbol, use engine oils that meet API Service SJ and/or ACEA A1-96, ACEA A2-96, or ACEA A3-96 requirements as shown in the chart. Page 4293 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 5396 Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. Page 13135 Abbreviations And Meanings Part 7 Page 10424 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 5608 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Recall - Flasher Relay Module Replacement Technical Service Bulletin # 05044 Date: 050728 Recall - Flasher Relay Module Replacement Bulletin No.: 05044 Date: July 28, 2005 SAFETY Subject: 05010 - INTERMITTENT INCORRECT TURN SIGNAL OPERATION Models: 2004 BUICK RAINIER 2003-2004 CHEVROLET TRAILBLAZER, TRAILBLAZER EXT 2003-2004 GMC ENVOY, ENVOY XL 2004 GMC ENVOY XUV 2003-2004 OLDSMOBILE BRAVADA Condition General Motors has decided that a detect, which relates to motor vehicle safety, exists in certain 2004 Buick Rainier and GMC Envoy XUV; 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles. Some of these vehicles have an intermittent condition in which the turn signals may not operate as designed. Material build up on the flasher relay may cause the turn signals to flash on both sides of the vehicle when activated similar to hazard warning flashers, or they may illuminate and remain illuminated instead of flashing. The instrument panel would indicate the incorrect operation if this were to occur. Incorrect operation of the turn signal indicator could fail to warn others of the driver's intentions and could lead to a vehicle crash. Correction Dealers are to replace the flasher relay module. Vehicles Involved Page 3886 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 10555 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 13446 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 7809 Steering Wheel: Service and Repair Steering Wheel Replacement Tools Required ^ J1859-A Steering Wheel Puller ^ J36541-A Steering Wheel Puller Adapter Removal Procedure Caution: Refer to Servicing the SIR System Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the inflator module. 3. Remove the horn plunger from the steering column by pressing inward to the stop and rotating horn plunger 90 degrees. 4. Disconnect the steering wheel electrical connector. 5. Remove the retaining nut which secures the steering wheel to the steering wheel shaft. Notice: When removing the steering wheel, use only the specified steering wheel puller. Do not hammer on the end of the steering column shaft. Hammering could loosen the plastic injections which maintain the steering column rigidity. Page 1403 Fuel Tank Pressure Sensor: Description and Operation The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 4115 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 8409 Registered And Non-Registered Trademarks Part 3 Page 4623 Step 6 Page 2260 Application Table Part 2 Page 5613 Disclaimer Recall - Flasher Relay Module Replacement Technical Service Bulletin # 05044 Date: 050728 Recall - Flasher Relay Module Replacement Bulletin No.: 05044 Date: July 28, 2005 SAFETY Subject: 05010 - INTERMITTENT INCORRECT TURN SIGNAL OPERATION Models: 2004 BUICK RAINIER 2003-2004 CHEVROLET TRAILBLAZER, TRAILBLAZER EXT 2003-2004 GMC ENVOY, ENVOY XL 2004 GMC ENVOY XUV 2003-2004 OLDSMOBILE BRAVADA Condition General Motors has decided that a detect, which relates to motor vehicle safety, exists in certain 2004 Buick Rainier and GMC Envoy XUV; 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT; GMC Envoy, Envoy XL; and Oldsmobile Bravada vehicles. Some of these vehicles have an intermittent condition in which the turn signals may not operate as designed. Material build up on the flasher relay may cause the turn signals to flash on both sides of the vehicle when activated similar to hazard warning flashers, or they may illuminate and remain illuminated instead of flashing. The instrument panel would indicate the incorrect operation if this were to occur. Incorrect operation of the turn signal indicator could fail to warn others of the driver's intentions and could lead to a vehicle crash. Correction Dealers are to replace the flasher relay module. Vehicles Involved Page 8627 Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Housing Assembly HVAC/Service and Repair 2. Remove the heater core access cover screws. 3. Remove the heater core access cover. 4. Remove the heater core (2) from the HVAC module assembly (1). INSTALLATION PROCEDURE 1. Install the heater core (2) to the HVAC module assembly (1). 2. Install the heater core access cover. 3. Install the heater core access cover screws. Tighten the screws to 1.9 N.m (17 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the HVAC module assembly. Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ....................................... 334 - 375 kPa (48 - 54 PSI) Fuel Pressure Drop (After 1 minute) ............................................................................................................................................................. 34 kPa (5 PSI) No. 2 Left Rear Seat Belt Retractor: Service and Repair No. 2 Left Rear REMOVAL PROCEDURE 1. Remove the rear seat belt upper guide shoulder bolt. 2. Remove the left rear quarter trim panel. 3. Remove the rear seat belt lower anchor nut. 4. Remove the bolt that retains the seat belt retractor assembly to the body. 5. Remove the seat belt retractor assembly from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt retractor assembly to the vehicle. 2. Install the seat belt retractor assembly to the vehicle NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat belt retractor bolts to 70 N.m (52 lb ft). 3. Install the left rear quarter trim panel. 4. Install the rear seat belt lower anchor nut. Ensure that the seat belt webbing is not twisted. Tighten Tighten the rear seat mounting nut to 45 N.m (33 lb ft). 5. Install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Page 4159 Steps 6-9 Page 8093 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 13006 Abbreviations And Meanings Part 7 Diagrams Seat Heater Sensor: Diagrams Heated Seat Element And Thermistor Assembly - Driver Back Page 2955 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 8203 Instrument Panel Carrier, Cowl Side Lower Console (w/Manual - HVAC System) (Body Type VIN 6) Service and Repair Headlamp Bulb: Service and Repair HEADLAMP BULB REPLACEMENT REMOVAL PROCEDURE CAUTION: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: Turn off the lamp switch and allow the bulb to cool before changing the bulb. - Leave the lamp switch OFF until the bulb change is complete. - Always wear eye protection when changing a halogen bulb. - Handle the bulb only by its base. Avoid touching the glass. - Keep dirt and moisture off the bulb. - Properly dispose of the used bulb. - Keep halogen bulbs out of the reach of children. NOTE: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe the bulb dry. 1. Open the hood. 2. Remove the headlamp. 3. Remove the access cover from the rear of the headlamp. 4. Disconnect the electrical connector from the socket. 5. Rotate the bulb and socket counter clockwise in order to remove the bulb and socket from the housing. 6. Disconnect the electrical connector from the socket. 7. Remove the bulb and socket from the headlamp. INSTALLATION PROCEDURE IMPORTANT: Replace a high beam bulb with another high beam bulb. The high beam bulb has a black socket. - Replace a low beam bulb with another low beam bulb. The low beam bulb has a gray tip and a grey socket. Page 4145 Registered And Non-Registered Trademarks Part 5 A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: Customer Interest A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 8177 For vehicles repaired under warranty, use the table. Disclaimer Page 12224 Power Seat Control Module: Diagrams Memory Seat Module - Driver C1 Page 6200 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 449 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 8814 2. Disconnect the electrical connector (2) from the air temperature sensor-upper right (1). 3. Remove the air temperature sensor-upper right (1) by turning the sensor clockwise and pulling out. INSTALLATION PROCEDURE 1. Install the air temperature sensor-upper right (1). 2. Connect the electrical connector (2) to the air temperature sensor-upper right (1). 3. Install the radio. A/C - Contaminated R134A Refrigerant Refrigerant: All Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Page 7989 1. Install the shock module yoke to the lower control arm stud and shock absorber. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shock module yoke to shock absorber pinch bolt and nut. Tighten the shock module yoke to shock absorber pinch bolt to 70 Nm (52 ft. lbs.). 3. Install the shock module yoke to lower control arm mounting nut. Tighten the shock module yoke to lower control arm mounting nut to 110 Nm (81 ft. lbs.). 4. Install the tire and wheel. 5. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when center punching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. Page 1129 Seat Adjuster Switch - Passenger (w/Heat) Part 1 Page 13119 Conversion - English/Metric Part 1 Page 11010 DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Page 2719 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Remove the oil fill cap. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the oil pan drain plug and drain the oil into a suitable container. Important: 0mCheck the old oil filter to ensure the filter seal is not left on the engine block. 4. Remove the oil filter using a suitable wrench. 5. Wipe the excess oil from the oil filter housing. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the new oil filter. Tighten the oil filter to 17 Nm (22 ft. lbs.) plus 150°. 3. Install the oil pan drain plug. Tighten the oil pan drain plug to 26 Nm (19 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity of engine oil. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. Page 10621 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 5480 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Page 2777 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 10216 Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 12491 Page 6425 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Page 12540 Abbreviations And Meanings Part 8 Page 7926 10. Remove the air spring level sensor to the frame mounting bolts. 11. Remove the air spring level sensor. Installation Procedure 1. Install the air spring level sensor link to the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not remove the air spring level sensor locating pin until the air spring level sensor has been properly aligned and the proper D height has been measured and maintained. 2. Install the air spring level sensor to the frame mounting bolts. Tighten the air spring level sensor to the frame mounting bolts to 8 Nm (6 lb ft). Page 4049 Engine Control Module: Description and Operation POWERTRAIN CONTROL MODULE (PCM) The PCM verifies that the password received from the theft deterrent control module via the serial data circuit is correct. The PCM can learn only one fuel continue password. If the fuel continue password is correct, the PCM enables the starting and fuel delivery systems. The PCM disables the starting and fuel delivery systems if any of the following conditions occur: - The fuel continue password is incorrect. - The fuel disable password is sent by the theft deterrent control module. - No passwords are received - there is no communication with the theft deterrent control module. The powertrain control module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. The PCM controls all ignition system functions, and constantly corrects the spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 4654 Steps 4-7 Page 4979 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. ^ Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install TCC PWM solenoid retainer. Page 7297 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 10439 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 3897 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 12656 Sunroof / Moonroof Switch: Service and Repair SUNROOF SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the overhead console in order to access the sunroof switch. 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat bladed tool carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. INSTALLATION PROCEDURE 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. Page 3527 Door Control Module Diagram 2 A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Shift Cable: Customer Interest A/T - No Start/MIL ON/DTC P0706/Indicator Inaccurate Bulletin No.: 04-07-30-029 Date: June 30, 2004 TECHNICAL Subject: Service Engine Soon (SES) Light On, Diagnostic Trouble Code (DTC) P0706, Gear Range Indicator Incorrect/Inaccurate, No Start (Reprogram Powertrain Control Module (PCM)) Models: 2003 Chevrolet and GMC Light Duty Trucks with 4L80-E Automatic Transmission (RPO MT1) or 4L85-E Automatic Transmission (RPO MN8) Condition Some customers may comment that the SES light is on. Some may comment that the vehicle will not start. Others may comment that the gear range indicator always reads "2" or "D2" regardless of the actual gear the transmission is in. Cause The original PCM diagnostic for DTC P0706 defaults the transmission position to Drive Range "2" when P0706 is set relating to the transmission range select circuit. Correction Follow the diagnostic tips and service procedure below to correct this condition. Diagnostic Tips ^ When DTC P0706 sets, the vehicle will not start. ^ For additional information on DTC P0706, refer to SI Document. ^ Check for proper operation and adjustment of the Park Neutral Position (PNP) switch. Refer to Park/Neutral Position Switch Adjustment. ^ Check for proper operation and adjustment of the Range Selector Cable. Refer to Automatic Transmission Range Selector Cable Adjustment. ^ Check for proper electrical connections and terminal integrity. ^ Inspect ground G103. ^ Check to determine if the PCM calibration has been previously updated to a calibration to include the update for throttle body coking. If the PCM currently has this coking calibration, it is not necessary to reprogram the PCM again. Repair Procedure 1. Diagnose and repair the cause of P0706. Page 2956 Registered And Non-Registered Trademarks Part 2 Page 10063 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Locations Impact Sensor: Locations Locations View Description and Operation Tachometer: Description and Operation TACHOMETER The IPC displays the engine speed based on the information from the PCM. The PCM converts the data from the engine speed sensor to a 2 pulses/engine revolution signal. The IPC uses the engine speed signal circuit (2 pulses/engine revolution) from the PCM in order to calculate the engine speed. If the IPC detects a malfunction in the engine speed signal circuit, the IPC uses the class 2 message from the PCM indicating the engine speed. Page 1742 Abbreviations And Meanings Part 6 Page 11696 11. With the sunshade parallel to the windshield, index the pivot arm tab to the roof panel slot. 12. Apply and maintain upward pressure to the pivot arm while rotating the sunshade parallel to the side window. The sunshade arm should appear flush with the bezel. 13. Rotate and clip the sunshade to the inboard retainer. 14. Ensure the pivot arm retaining tabs are fully seated to the roof panel. 15. Install the front assist handle to the roof panel. 16. Install the windshield garnish molding. 17. Install the center pillar trim panel. 18. Return the bucket seat to an upright position. Page 2421 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 10635 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Locations Connector C201 Page 2981 6. Remove the air pressure to the cylinder. 7. Coat the camshaft journals, the camshaft journal thrust face, and the camshaft lobes with clean engine oil. 8. Install the camshafts to their original position. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 9. Install the camshaft caps onto their original journal. Tighten the camshaft cap bolts to 12 Nm (106 inch lbs.). 10. Carefully move the camshaft sprockets back onto the camshafts and remove the J 44222. 11. Install the intake camshaft sprocket washer and the bolt, and the exhaust camshaft actuator bolt. - Tighten the intake camshaft sprocket bolt the first pass to 20 Nm (15 ft. lbs.). - Use the J 36660-A to tighten the intake camshaft sprocket bolt the final pass and additional 100°. - Tighten the exhaust camshaft actuator bolt the first pass to 25 Nm (18 ft. lbs.). - Use the J 36660-A to tighten the exhaust camshaft actuator bolt a final pass an additional 135°. Page 4219 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 2841 Oil Pressure Sensor: Diagrams Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 12388 Position Sensor - Recline Motor (w/Memory) Page 4527 Steps 10-13 Page 4146 Registered And Non-Registered Trademarks Part 6 Page 3910 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: All Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Page 12105 Front Passenger Door Module (FPDM) Page 9808 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Specifications Camshaft Bearing: Specifications Camshaft Cap Bolt 106 inch lbs. Page 1755 Abbreviations And Meanings Part 19 Page 2385 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 7564 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 5814 7. Remove the inner pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. Installation Procedure 1. Install the outer pinion bearing cup using the J7817, 8.0 inch axle, or the J8611-01, 8.6 inch axle (1), and the J8092 (2). 2. Install the inner pinion bearing cup. using the J8608 (2) and the J8092 (1). 3. Determine the selective shim thickness for the pinion. Page 12708 To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information outlined in this bulletin will assist technicians in the replacement of the revised AIP seal. Remove the original rear hood (AIP) seal to the air inlet grille panel staked studs. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Cut three or four slits through the original rear hood (AIP) seal to the air inlet grille panel plastic staked studs. Carefully remove the rear hood (AIP) seal from the staked plastic studs. Do Not cut off the top or staked portion of the plastic studs holding the rear hood (AIP) seal to the air inlet grille panel. If removed, the air inlet grille panel will have to be replaced. Refer to the above illustration (1). DO NOT remove the air inlet grille panel from vehicle, Illustration purpose Only. Page 9330 Page 753 Control Module HVAC: Service and Repair Control Module HVAC - Auxiliary Auxiliary Heater and Air Conditioning Control Module Replacement Removal Procedure 1. Using a flat bladed tool, carefully pry out on the top of the HVAC control-auxiliary. 2. Remove the HVAC control-auxiliary from the center console/seat. 3. Disconnect the electrical connector. 4 remove the HVAC control-auxiliary. Installation Procedure Page 10873 Abbreviations And Meanings Part 9 Page 8895 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the grille. 6. Remove sensor bracket from bumper. 7. Remove the Connector Position Assurance (CPA) from both (2) electronic frontal sensor (EFS) connectors. IMPORTANT: This vehicle is equipped with two inflatable restraint electronic frontal sensors (EFS). When performing this procedure be sure to include both EFS's. 8. Disconnect both EFS connectors. Zone 2 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. Page 1436 Exhaust Pipe Page 8189 10. Connect the electrical connector to the A/C low pressure switch. 11. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 12. Leak test the fitting of the component using the J 39400-A. Page 12892 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 7651 1. Install the power steering cooler to the radiator support. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the power steering cooler mounting bolts. Tighten the power steering cooler mounting bolts to 20 Nm (15 ft. lbs.). 3. Connect the power steering hoses assembly to the power steering cooler. 4. Remove drain pan from under the vehicle. 5. Install the radiator air intake baffle. Page 2748 10. Disconnect the prop shaft from the front axle pinion yoke. 11. Remove the oil pan drain plug and drain the oil. 12. Unclip the transmission cooler lines from the engine block. 13. Remove the front differential bolts and set aside the front differential. 14. Remove 4 transmission bell housing bolts that are attached to the oil pan. 15. Remove the remaining oil pan bolts. 16. Place 2 oil pan bolts in the jack screws on the oil pan and tighten evenly to release the oil pan from the engine. 17. Clean and inspect the oil pan. Installation Procedure Important: The oil pan must be installed within 10 minutes from when sealer was applied 1. Apply a 3 mm (0.12 inch) bead of sealer GM PN 12378521 to the block, rather than the oil pan. Important: When you install the oil pan, it could be shifted front or back a little which could cause a transmission alignment problem. The back of the oil pan needs to be flush with the block. 2. Install the oil pan, maneuvering the oil pan to clear the oil pump and screen assembly. 3. Install the oil pan bolts. Page 11890 Tighten Tighten the screws to 0.75 N.m (6 lb in). 5. Install the lock to the door. 6. Install the water deflector. 7. Install the door trim panel. Lock Actuator Replacement - Rear Door LOCK ACTUATOR REPLACEMENT - REAR DOOR REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the door latch assembly. 4. Remove the 2 screws that retain the actuator (1) to the lock. 5. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. 6. Remove the actuator from the latch. INSTALLATION PROCEDURE Page 12146 Conversion - English/Metric Part 1 Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor (VSS) Page 1526 47. Connect the electrical connector to the A/C low pressure switch. 48. Install the lower air cleaner housing/washer solvent tank assembly onto the mounting studs. 49. Install the two air cleaner housing/washer tank assembly retaining nuts to the mounting studs. 50. Connect the washer pump hoses. 51. Connect the washer solvent tank electrical and install wiring harness to the retaining clips. 52. Install the air inlet duct to the lower air cleaner housing/washer solvent tank assembly. 53. Install the air cleaner filter element and air outlet duct. 54. Install the air cleaner cover. 55. Install the tender rear upper brace. 56. Connect the negative battery cable. 57. Recharge the refrigerant system. 58. Fill the cooling system. 59. Inspect the cooling system for leaks. 60. Leak test the refrigerant fittings using J 39400-A. Parts Information Warranty Information Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 13931 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 11411 4. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the C clip to the groove in the lock cylinder. 3. Install the lock rod to the lock cylinder. 4. Install the rear wiper motor. Page 9123 Page 10330 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 270 Labor Time Information Diagrams Hood Ajar Switch (Export) Page 3437 Specifications Oil Pump Cover: Specifications Oil Pump Cover Bolt 89 inch lbs. Page 3131 Spark Plug: Testing and Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 1736 depth. CAUTION: Refer to Safety Glasses Caution in Service Precautions. IMPORTANT:Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.Avoid any buildup of chips. Back out the tap every few turns and remove the chips. 2. Drill out the damaged threads. Clean out any chips. 3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads. 4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. 5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert. IMPORTANT:The insert should be flush to one turn below the surface. 6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift. Training TRAINING DEALERS All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888- 748-2686. The help desk is available Monday through Friday, 8:00 A.M. - 8:00 P.M. Eastern Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888- 337-1010. FLEETS GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC). Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831. NOTE: Most GM STC course materials have associated charges. To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831. NON-GM DEALER TECHNICIANS Technicians training for non-GM dealers is available through AC Delco. This training is for AC Delco customers employed in the automotive or truck service industry. AC Delco courses are available at the GM Training Center course. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through AC Delco Warehouse Distributors. Page 7115 C315 Part 1 Page 7857 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the fuel tank shield. 3. Remove the evaporative emission (EVAP) canister from its mounting bracket. Do not disconnect the canister lines. 4. Support the transmission with a transmission jack. 5. Remove the transmission mount to the transmission support retaining nuts. 6. Remove the lower transmission support to the frame mounting bolts. 7. Remove the upper transmission support to the frame mounting bolts. 8. Remove the transmission support from the frame. Installation Procedure Page 11800 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 9387 Abbreviations And Meanings Part 21 Page 14026 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 6312 1. Install the backing plate to the axle housing flange. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backing plate nuts. ^ Tighten the backing plate bolts to 135 Nm (100 ft. lbs.). 3. Install the rear drive axle. 4. Install the park brake shoe. Page 9126 Page 6127 Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Remove the accessory trim plate. 2. Disconnect the electrical connector from the traction control switch. 3. Release the traction control switch locking tabs located behind the trim plate. 4. Remove the traction control switch from the trim plate Installation Procedure 1. Position the traction control switch to the trim plate 2. Install the traction control switch to the instrument panel trim plate by seating the locking tabs. 3. Connect the electrical connector to the traction control switch. 4. Install the accessory trim plate. Page 9803 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Recall 04V046000: Erratic Wiper Operation Wiper Control Module: All Technical Service Bulletins Recall 04V046000: Erratic Wiper Operation DEFECT: The windshield wipers on these sport utility vehicles may fail to turn on, unexpectedly stop working, fail to turn off/on by themselves (moisture sensitive wiper system), or the washer pump may operate continuously because water can enter the wiper module and either cause a short circuit or corrosion of components within the module. Driver visibility could be reduced, which could result in a crash. REMEDY: Dealers will cover the windshield wiper module vent hole with a patch. Also, the wiper motor, circuit board, and electrical connector will be inspected for signs of water intrusion and/or corrosion and be replaced as required. The manufacturer has reported that owner notification is expected to begin during the third quarter of 2004. Owners may contact Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Oldsmobile at 1-800-630-6537. Page 12829 Abbreviations And Meanings Part 6 Page 3911 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 12207 3. Install the screw that retains the seat control module to the seat pan. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat module screw to 3 N.m (26 lb in). 4. Install the seat pan to the seat assembly. 5. Install the nuts which retain the seat pan to the seat assembly. Tighten Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 6. Install the 3 seat switch bezel screws. Description and Operation Temperature Warning Lamp/Indicator: Description and Operation Engine Coolant Indicator ENGINE COOLANT HOT IDLE ENGINE The radio activates an audible warning as requested by the Instrument Panel Cluster (IPC). The IPC sends a class 2 message to the radio indicating the chime duration of 4 pulses. The warning sounds and the appropriate indicator illuminates in the Driver Information Center (DIC) when the following occurs: - The IPC determines that the coolant temperature is greater than 125°C (257°F). The IPC receives a class 2 message from the PCM indicating coolant temperature. - The IPC performs the displays test at the start of each ignition cycle. The indicator illuminates for approximately 3 seconds. The IPC turns OFF the engine coolant indicator when the engine coolant falls below 122°C (252°F). Page 10393 Steps 8-12 Page 12603 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the passenger door module (1). 4. If replacing only the passenger door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the passenger door module for transfer. 7. Remove the switch panel assembly from the vehicle. Installation Procedure 1. Install the passenger door module (1) to the door trim panel. 2. Connect the electrical connector to the passenger door module. 3. If replacing the switch panel, connect the remaining electrical connectors. Important: When replacing the passenger door module, the set up procedure must be performed. 4. If replacing the passenger door module, program the passenger door module. Refer to Service Programming System (SPS) (Remote Procedure) Service Programming System (SPS) (Pass-Thru Procedure) Service Programming System (SPS) (Off Board Remote Procedure) Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Page 38 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 8448 A/C Compressor Clutch Assembly (w/Automatic - HVAC System) Page 11634 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 7. Disconnect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. Zone 5 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Access IP module connector through glove box. 5. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. Page 8945 Impact Sensor: Description and Operation INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The Side Impact Sensor (SIS) contains a sensing device (accelerometer) which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant air bag deployment. The SIS is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops deploying the side air bags. Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: All Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 1943 2. Install the spark plugs to the engine. Tighten the spark plugs to 18 Nm (13 lb ft). 3. Install the ignition coils. Refer to Ignition Coil Replacement. Page 10690 Labor Time Information Body - Erratic Outside Rearview Mirror Operation Power Mirror Control Module: All Technical Service Bulletins Body - Erratic Outside Rearview Mirror Operation File In Section: 08 - Body and Accessories Bulletin No.: 02-08-64-021 Date: October, 2002 TECHNICAL Subject: Outside Rearview Mirrors Do Not Return To Their Original Position After Using Curb View Assist Feature (Update Door Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada with Outside Rearview Mirror Curb View Assist Feature (RPOs D25 or D53) Condition Some customers may comment that the outside rearview mirrors do not return to their original position after using the reverse tilt (curb view assist) feature. Correction Update the driver and passenger door modules with new software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. Please refer the vehicle owner to the appropriate sections in their Owner's Manual for more information on the operation of the rearview mirrors and personalization instructions. A new driver and passenger door module was put into production vehicles starting in August 2002. All 2002 model year vehicles may need the software update. All 2003 model year vehicles built in August 2002 and earlier may need the software update. If the software update does not fix the concern, perform the Diagnostic System Check - Door Systems and repair as necessary. Warranty Information For vehicles repaired under warranty, use the table shown. DISCLAIMER Page 13963 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 10890 Abbreviations And Meanings Part 26 Page 11641 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 4. Install the LF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 12960 Knock Sensor (KS) 1 Front Knock Sensor (KS) 1 Front Page 1357 Turn Signal Switch: Service and Repair Multifunction Turn Signal Switch Housing Replacement Multifunction Turn Signal Switch Housing Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the steering wheel from the column. 3. Remove the ignition lock cylinder case assembly. 4. Remove the turn signal and multifunction switch assembly. 5. Slide the turn signal switch housing off of the steering column shaft assembly. Installation Procedure Important: The turn signal switch housing must be pressed firmly against the steering column tilt head in order for the screws from the turn signal and multifunction switch assembly screws to line up. 1. Slide the turn signal switch housing onto the steering column shah assembly. 2. Install the turn signal and multifunction switch assembly. 3. Install the ignition lock cylinder case. 4. Install the steering wheel onto the column. 5. Enable the SIR system. Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Page 6254 9. Install the rear brake caliper assembly. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Refer to Vehicle Lifting. Caution: Refer to Firm Brake Pedal Caution in Service Precautions. 12. Pump the brake pedal slowly and firmly in order to seat the brake pads. Page 8035 Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Page 13936 Abbreviations And Meanings Part 6 Page 13435 Page 4128 Abbreviations And Meanings Part 14 Page 779 this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT RECALL CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the Claim Form provided to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. All recall reimbursement questions should be directed to the following number: 1-800-204-0261. Disclaimer Service Procedure Page 4127 Abbreviations And Meanings Part 13 Page 8367 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 12086 Paint: Service and Repair Basecoat/Clearcoat Paint Systems Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Caution: Refer to Eye Protection Caution in Service Precautions. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D-99 identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers. If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clearcoat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel.) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: * Lifting of primer coats caused by overly aggressive solvents in subsequent layers * Loss of adhesion between layers due to incompatibility of resin systems * Solvent popping or pinholing due to inappropriate solvent selection * Poor through-curing due to incompatible hardener resins or insufficient reactivity * Gloss reduction due to incompatible resins and/or solvents * Poor color accuracy due to pigment interactions with incompatible resins and/or solvents * Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Page 7126 C800 Part 2 Page 11135 An initial supply of weatherstrips required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of February 6, 2006, and will be approximately 10% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account. Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Important: It is estimated that less than 10% of involved vehicles will require lock replacement. Please order parts accordingly. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to the recall condition are to be submitted to dealers by February 28, 2007. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Claim Information Page 2574 Engine Block Heater: Service and Repair Heater Cord Coolant Heater Cord Replacement Removal Procedure 1. If equipped with a 4.2L engine, remove the PCM. 2. Remove the coolant heater cord from the engine harness bracket (1). 3. Remove the coolant heater cord from the coolant heater (2). 4. If equipped with a 5.3L engine, disconnect the coolant heater cord from the coolant heater (1). 5. Remove the coolant heater cord clip from the engine harness. 6. Disconnect the coolant heater cord retainers (1) from the battery cover. Installation Procedure Page 15 Page 849 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Assist Step Support Bracket Replacement Auxiliary Step / Running Board: Service and Repair Assist Step Support Bracket Replacement Assist Step Support Bracket Replacement Removal Procedure 1. Remove the bolts that retain the assist step support brackets to the body. 2. Remove the assist step assembly from the vehicle. 3. Place the step assembly on a clean, prepared surface. 4. Remove the nuts (1) that retain the assist step to the support brackets. 5. Remove the support brackets from the assist step. Installation Procedure 1. Position the assist step to the support brackets. Notice: Refer to Fastener Notice in Service Precautions. Install the nuts (1) that retain the assist step to the support brackets. Tighten the nuts to 25 N.m (18 lb ft). Page 4657 Steps 14-15 Page 4536 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic converter. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Page 4430 Manifold Absolute Pressure (MAP) Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 3. Press the retainer locking tabs inward, then pull the retainer (1) up to remove it. 4. Remove the MAP sensor (2). 5. Inspect the MAP sensor seal for damage, and replace as necessary. INSTALLATION PROCEDURE Page 12891 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Page 4032 Engine Harness, Fuse Block-Underhood Specifications Page 9078 Seat Belt Retractor: Service and Repair No. 1 Center Rear REMOVAL PROCEDURE 1. Remove the rear seat back assembly. 2. Remove the rear seat belt anchor nut from the seat belt buckle bracket. 3. Remove the rear seat back seat belt bezel by pressing in the buttons (1) on the plastic retainers. 4. Remove the seat belt bezel from the seat belt. 5. Remove the seat back cover and pad. Page 143 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. A/C - Intermittently Inoperative/Poor Performance Control Module HVAC: All Technical Service Bulletins A/C - Intermittently Inoperative/Poor Performance Bulletin No.: 02-01-39-005A Date: August 17, 2005 TECHNICAL Subject: HVAC System Inoperative For A Drive Cycle, Poor HVAC System Performance In High Ambient Temperatures (Update HVAC Control Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to correct the RPO usage information below: RPO CJ2 = HVAC System Air Conditioner Front, Automatic Temperature Control, Auxiliary Temperature Control RPO CJ3 = HVAC System Air Conditioner Front, Manual Temperature Control, Auxiliary Temperature Control Please discard Corporate Bulletin Number 02-01-39-005 (Section 01 - HVAC). Condition Some customers may comment about no cold air from the heating, ventilation and air conditioning (HVAC) system during a drive cycle. This concern may occur at any time during the drive cycle and at any temperature setting. The HVAC system operation returns to normal after the vehicle has been keyed to off and restarted. This concern is intermittent and most likely to occur on hot days. This concern may be found on vehicles equipped with manual (CJ3) and automatic (CJ2) HVAC systems. Other customers may comment about poor HVAC system performance in high ambient temperature conditions. This concern may be present in automatic (CJ2) HVAC systems only. An HVAC control module software update was put into all production vehicles beginning in September 2002. Vehicles built in September 2002 and earlier may need this software update. Correction Update the HVAC control module using software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. This software update addresses both the intermittent no cooling and the poor performance concerns. If the software update does not correct the concerns, perform the HVAC Diagnostic System Check and repair as necessary. If the HVAC control module is replaced with a part from GMSPO, make sure the module has the latest software update. The module may need to be updated even though it is a new part. Warranty Information Disclaimer Page 13599 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13534 Miniwedge (Door Jamb Switch) - RF Page 2977 Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Tools Required - J 38820 Valve Stem Seal Remover and Installer - J 44222 Camshaft Sprocket Holding Tool - J 44228 Valve Spring Compressor Removal Procedure Important: Organize the valve train components when disassembling so they can be reassembled in the same location and matched up with the same components, as previously installed. 1. Remove the cam cover. 2. Remove the spark plugs. 3. Remove the exhaust and the intake sprocket bolts. 4. Install the J 44222 onto the cylinder head in order to keep from disturbing the timing chain components. 5. Adjust the 2 horizontal bolts into the camshaft sprockets to maintain chain tension. 6. Carefully move the sprockets with the timing chain, off of the camshafts. 7. Remove the camshaft cap bolts. Important: Place the camshaft caps in a rack to ensure the caps are installed in the same location from which they were removed. 8. Remove the camshaft caps. Page 5891 9. Assemble the bearing retainer in the retainer groove. 10. Continue pressing until both retainers can be snapped into place. 11. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a dead blow hammer. 12. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. Page 10829 Page 13292 Registered And Non-Registered Trademarks Part 4 Page 8241 4. Install the screws to the HVAC module assembly. Tighten Tighten the screws to 1.9 N.m (17 lb in). 5. Install the HVAC module assembly. 6. Recalibrate the recirculation actuator on vehicles equipped with automatic climate control (C68), See: Testing and Inspection/Programming and Relearning Recall 05V198000: Flasher Module Replacement Turn Signal Flasher: All Technical Service Bulletins Recall 05V198000: Flasher Module Replacement MAKE/MODELS: MODEL/BUILD YEARS: Buick/Rainier 2004 Chevrolet/Trailblazer 2003-2004 GMC/Envoy 2003-2004 Isuzu/Ascender 2003-2004 Oldsmobile/Bravada 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V198000 RECALL DATE: April 29, 2005 COMPONENT: Exterior Lighting: Turn Signal POTENTIAL NUMBER OF UNITS AFFECTED: 286478 SUMMARY: On certain trucks and sport utility vehicles, the driver wishing to signal a turn by moving the directional signal lever, (up or down) may cause the front marker/turn lights and rear turn lights to flash in a manner similar to hazard warning, rather than flashing on the desired side only. CONSEQUENCE: The driver may not be able to clearly signal their intentions to turn, change travel lanes, or potentially warn others of an impaired vehicle operating condition increasing the risk of a crash. REMEDY: Dealers will replace the suspect flasher modules with a new flasher module designed with sealed relays and more durable contact material inside of the relays. The recall is expected to begin during August 2005. owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, Isuzu at 1-800-255-6727, Buick at 1-866-608-8080, and Oldsmobile at 1-800-630-6537. NOTES: GM recall No. 05044. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Fuse Block - Rear (Short Wheelbase) Fuse: Application and ID Fuse Block - Rear (Short Wheelbase) Location View Page 9835 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 8731 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ......................................................................................................................................... Polyalkaline Glycol (PAG) Refrigerant Oil Page 148 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 76 Abbreviations And Meanings Part 21 Page 9340 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 3080 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the fuel pressure service connection cap. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Install the fuel tank shield if removed. Page 2175 6. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 7. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Zone 6 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the RF door trim panel. Page 4268 Abbreviations And Meanings Part 2 Page 10410 Page 9289 Alarm Module: Description and Operation THEFT DETERRENT CONTROL MODULE Vehicles with steering column mounted ignition switches have the exciter integral with the theft deterrent control module which is located within the steering column. Vehicles with instrument panel mounted ignition switches have exciter modules separate from the theft deterrent control module with the vehicle wiring harness connecting the two. The theft deterrent control module for vehicles with instrument panel mounted ignition switches is located within the instrument panel. The theft deterrent control module can learn up to ten keys (transponder values). The theft deterrent control module uses the following inputs, battery voltage, ignition switched voltage and ground circuit. The theft deterrent control module uses the following outputs, password exchange with the PCM, fuel enable/disable via the serial data circuit. When an ignition key is inserted into the ignition lock cylinder and the ignition is switched ON, the transponder embedded in the head of the key is energized by the exciter coils surrounding the ignition lock cylinder. The energized transponder transmits a signal that contains its unique value, which is received by the theft deterrent control module. The theft deterrent control module then compares this value to a value stored in memory, learned key code. If the value is correct the theft deterrent control module sends a random generated number to the transponder, this is called a challenge. Both the transponder and the theft deterrent control module perform a calculation on the challenge. The theft deterrent control module then performs one of the following functions: - If both the transponder value and the calculation to the challenge are correct, the theft deterrent control module will send the fuel continue password to the PCM via the serial data circuit. - If either the transponders unique value or the calculation to the challenge is incorrect the theft deterrent control module will send the fuel disable password to the PCM via the serial data circuit. - If the theft deterrent control module is unable to measure the ignition key transponder value for one second due to a damaged or missing pellet or a damaged exciter, the theft deterrent control module will send the fuel disable password to the PCM via the serial data circuit. Page 10847 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 6381 Page 7339 Fuse Block - Rear C3 Part 2 Page 10300 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 13059 6. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 7. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 8. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 9. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. 10. Install the SIR fuse to the fuse block (1) located in the underhood electrical center. 11. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 11.1. The AIR BAG indicator will flash 7 times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition. Page 12175 Abbreviations And Meanings Part 20 Multifunction, Turn Signal Switch Replacement Turn Signal Switch: Service and Repair Multifunction, Turn Signal Switch Replacement Multifunction, Turn Signal Switch Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the upper and lower trim covers. 3. Tilt the column to the CENTER position. 4. Disconnect the connectors from the turn signal and multifunction switch assembly. Remove 2 pan head tapping screws from the turn signal and multifunction switch assembly. 5. Remove the turn signal and multifunction switch assembly. Installation Procedure Important: The electrical contact on the turn signal and multifunction switch assembly must rest on the turn signal cancel cam assembly. 1. Install the turn signal and multifunction switch assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Secure by using 2 pan head tapping screws. - Tighten the screw on the top of the column to 3 Nm (27 inch lbs.). - Tighten the screw in the front to 7 Nm (62 inch lbs.). 3. Connect the connectors to the turn signal and multifunction switch assembly. 4. Install the upper and lower trim covers. 5. Enable the SIR system. Page 2397 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Locations Engine, Left Side Page 2562 Important: Before using trim tool assembly EN 45680-411 the height of the cutting blades must be set to the proper specification. The proper specification is that the cylinder bore sleeve flange must be flush to +0.02 mm (0.0008 in) above the block deck surface. 5. The groove side of the set gage ring EN 45680-412 (1) should be positioned upward on a flat surface. Important: Ensure that the set gage ring EN 45680-412 surfaces are clean. 6. Carefully position trim tool assembly EN 45680-411 onto the set gage ring EN 45680-412. 7. Loosen the shaft collar screw (2). 8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3). Important: Once this procedure is done, it is not necessary to reset the trim tool assembly EN 45680-411 height until the blades are worn or damaged. 9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten Tighten the shaft collar screw to 19 Nm (14 lb ft). Page 1694 HVAC System - Manual Low Pressure Sensor / Switch: Description and Operation HVAC System - Manual HVAC SYSTEM - MANUAL A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 12 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 124 kPa (18 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275 kPa (40 psi). This enables the A/C compressor to turn back ON. Page 1841 Steps 4-7 Page 1507 34. Install the coolant bypass valve to its original location and secure with a nut. 35. Connect the other end of the new hose from step 29 to the outlet port of the auxiliary heater pump. 36. Connect the vacuum hose to the coolant bypass valve. 37. Connect the coolant bypass valve hose to the auxiliary rear heater line. 38. Install the heater hose quick connect retainers to the heater core pipes. 39. Connect the remaining two hoses to the heater core. 40. Install the new auxiliary heater pump wiring harness to the vehicle. Page 3885 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 12359 Memory Seat Module - Driver C4 Part 2 Page 10632 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 14016 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 13241 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 13124 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 11178 Page 1819 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Page 8555 line and the A/C component. Page 3399 Water Pump: Service and Repair Water Pump Replacement (4.2L Engine) Tool Required J 41240 Fan Clutch Wrench Removal Procedure 1. Drain the coolant. 2. Remove the fan and shroud. 3. Remove the drive belt. 4. Using the J 41240, secure the water pump pulley and remove the water pump pulley bolts. 5. Remove the J 41240. 6. Remove the water pump pulley. 7. Loosen and remove the water pump bolts. 8. Remove the water pump. 9. Clean and inspect the water pump. 10. Discard and replace the gasket. Installation Procedure Page 12029 WA8554/40 - WA8554/40 Page 10540 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Specifications Ride Height Sensor: Specifications Air Spring Leveling Sensor to Frame Mounting Bolts 7 ft. lbs. Page 7100 C305 Part 1 Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 9321 Page 6622 Positive: Vehicle Damage Warnings BATTERY DISCONNECT CAUTION CAUTION: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. Page 2685 See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the right frame engine mount bracket bolts. if removed. Tighten the mount bracket bolts to 110 Nm (81 ft. lbs.). 3. Note: Graphic shows left, right is similar. Install the right engine mount bracket and secure with the bolts (1). Tighten the engine mount bracket bolts to 50 Nm (37 ft. lbs.). 4. Install the right engine mount. 5. Lower the engine onto the engine mounts. 6. Install the right and the left upper engine mount nuts. Tighten the upper engine mount nuts to 70 Nm (52 ft. lbs.). Page 10151 Page 4209 Tighten Tighten the HO2S to 41 N.m (30 lb ft). 3. Connect the HO2S electrical connector (1). Page 7385 8. Release the tabs that retain the junction block to the block base. 9. Remove the junction block from the block base. 10. Disconnect the instrument panel harness connector (1) from the junction block. 11. Disconnect the mobile telephone harness connector (1) from the junction block. Page 3801 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 7823 Important: ^ The vehicle must rest on a level surface. ^ The vehicle must be stable. Do not rock the vehicle on the floor stands. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Clean and inspect the ball joint seal for cuts or tears. If the ball joint seal is damaged, replace the ball joint. Refer to Lower Control Arm Ball Joint Replacement or Lower Control Arm Replacement. 3. Support the lower control arm with a floor stand as far outboard as possible and raise suspension to just below the ride height. 4. Install the J 8001 or a suitable dial indicator in a way to measure the vertical lash in ball joint. Notice: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). 5. Gently lift or pry the suspension to induce the ball joint movement. 6. If the dial indicator reading is more than 1.524 mm (0.060 in), replace the lower ball joint. Refer to Lower Control Arm Ball Joint Replacement or Lower Control Arm Replacement. Page 597 Abbreviations And Meanings Part 9 Page 12459 7. Connect the J-strips that retain the cover to the seat pan. Seat Cushion Cover and Pad Replacement - Rear No. 2 SEAT CUSHION COVER AND PAD REPLACEMENT - REAR NO. 2 REMOVAL PROCEDURE 1. Remove the two bolts (2) securing the rear seat cushion assembly (1) to the seat latch rod (3). 2. Remove the rear seat cushion assembly. 3. Remove the pull handle assembly (1). 4. Remove the J-strips (2) securing the rear seat cushion cover to the seat cushion panel. Page 438 Page 2197 Location View Page 4210 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 2 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). 3. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must reinstall the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. 2. Install the heated oxygen sensor (2) using a J 39194-B. Page 6684 Abbreviations And Meanings Part 6 Page 10826 Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Page 8471 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13125 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Technician Safety Information Paint: Technician Safety Information Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Page 5167 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Slde Page 3736 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Page 7128 C901 Diagrams Cornering Lamp: Diagrams Cornering Lamp - Left Page 12050 WA379E/86 - WA382E/11 Page 11643 2. Connect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 3. Install the CPA (3) to the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 4. Install the RF door trim panel. 5. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 6. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Remove the key from the ignition. 2. Connect the LF side impact module yellow 2-way connector (1) located under the driver seat. 3. Install the CPA to the LF side impact module yellow 2-way connector (1) located under the driver seat. Page 6507 Parking Brake Shoe: Service and Repair Park Brake Shoe Replacement (Rear Disc Brakes) Removal Procedure Caution: Refer to Brake Dust Caution in Service Precautions 1. Release the park brake, if applied. 2. Raise and the vehicle. Refer to Vehicle Lifting. 3. Remove the wheel and the tire. Important: In the following service procedure, the brake caliper and mounting bracket does not have to be separated. Relocated the brake caliper and bracket to the side and secure. 4. Remove the brake caliper and bracket. 5. Remove the brake rotor. Page 13215 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 9165 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 14019 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 543 Page 12607 Power Mirror Switch: Service and Repair POWER MIRROR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Carefully use a flat-bladed tool in order to release the outside mirror switch retaining tabs from the trim panel. 2. Remove the outside mirror switch from the trim panel. 3. Disconnect the electrical connector from the power folding mirror switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power folding mirror switch. 2. Position the power folding mirror switch to the door trim panel. 3. Apply downward pressure to the power folding mirror switch, ensuring the retaining tabs are fully seated. Page 13921 Conversion - English/Metric Part 1 Description and Operation Air Cleaner Restriction Indicator: Description and Operation The air cleaner restriction indicator is located on the intake duct between the air cleaner assembly and the throttle body. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Page 8607 Expansion Block/Orifice Tube: Service and Repair Body VIN 6 / GMT 370 EXPANSION (ORIFICE) TUBE REPLACEMENT (BODY VIN CODE 6) TOOLS REQUIRED - J 26549-E Orifice Tube Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Remove the accumulator. 3. Remove the coolant reservoir. 4. Loosen the evaporator tube nut (5) from the evaporator. 5. Remove the evaporator tube from the evaporator. 6. Remove the nut (2) from the evaporator tube block (3). 7. Separate the evaporator tube at the block fitting (3). 8. Use the J 26549-E in order to remove the expansion tube (4). 9. Remove the O-ring seal and discard. 10. Remove the expansion tube (4) from the evaporator tube (1). INSTALLATION PROCEDURE Page 567 TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS Page 128 Page 6399 Submit a Product Recall Claim with the information shown CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter shown. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 11225 7. Install the window regulator. 8. Install the water deflector. 9. Install the outer window belt sealing strip. 10. Install the inner window belt sealing strip. 11. Install the trim panel. Window Weatherstrip Run Channel Assembly Replacement - Rear (TrailBlazer, Envoy, Bravada) Window Weatherstrip Run Channel Assembly Replacement - Rear (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the trim panel. 2. Remove the inner window belt sealing strip. 3. Remove the outer window belt sealing strip. 4. Remove the water deflector. 5. Remove the window. 6. Remove the bolt that retains the weatherstrip run channel to the door. 7. Pull the weatherstrip/run channel from the window frame opening. 8. carefully release the double sided tape attaching the molding to the outside of the door. 9. Carefully twist the weatherstrip run channel and pull up at the top of the door frame. Important: The quarter glass and weatherstrip/run channel is not serviceable and should be replaced only as an assembly. 10. Remove the weatherstrip/run channel from the door. Installation Procedure 1. Install the weatherstrip/run channel to the door. 2. Press the weatherstrip/run channel into the window frame opening. 3. Position the tabs on the weatherstrip/run channel into the slots on the door. 4. Attach the molding to the outside of the door with double sided tape. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the weatherstrip/run channel retaining bolt. Tighten the bolt to 10 N.m (88 lb in). 6. Install the window. 7. Install the water deflector. 8. Install the outer window belt sealing strip 9. Install the inner window belt sealing strip. 10. Install the trim panel. Page 8500 HVAC Control Module - Auxiliary (Body Type VIN 3) Page 4966 Shift Solenoid: Diagrams 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Slde Page 13219 Page 1461 Accelerator Pedal Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor retaining fasteners. 3. Remove the APP sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the APP sensor (2) to vehicle. 2. Install the APP sensor retaining fasteners (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining fasteners to 10 N.m (89 lb in). 3. Connect the APP sensor electrical connector. Page 13693 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the windshield garnish moldings. 2. Remove the trim pad. 3. Disconnect the electrical connector from the sensor. IMPORTANT: Cover the windshield defrost vents with clean shop rags. 4. In order to remove the sensor from the trim pad, rotate the sensor counter-clockwise 1/4 turn. 5. Remove the sensor from the trim pad. INSTALLATION PROCEDURE Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Page 3941 Registered And Non-Registered Trademarks Part 2 Page 10289 Speaker: Service and Repair Speaker Replacement - Rear Door SPEAKER REPLACEMENT - REAR DOOR REMOVAL PROCEDURE 1. Remove the rear door trim panel. 2. Remove the water deflector. 3. Disconnect the speaker electrical connector. 4. Remove the 3 speaker retaining bolts. 5. Remove the speaker from the door. INSTALLATION PROCEDURE 1. Install the speaker to the door. 2. Install the 3 speaker retaining bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the speaker electrical connector. 4. Install the water deflector. 5. Install the rear door trim panel. Service and Repair Seat Latch: Service and Repair SEAT LATCH ROD REPLACEMENT - REAR NO. 2 REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the two bolts (2) securing the rear seat cushion assembly (1) to the seat latch rod (3). 3. Remove the seat riser latch assembly (1) from the seat latch rod (2). Page 9202 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION RETAINED ACCESSORY POWER (RAP) POWER MODE RAP is a power mode that permits the operation of selected customer convenience items for 10 minutes after the ignition switch is turned OFF. RAP power mode is enabled by the BCM. The BCM: controls certain body functions. - sends out a class 2 message via the serial data line, which enables/disables other modules at the beginning/end of RAP power mode. Some BCM features, such as the interior courtesy lamps will function after the 10 minute RAP time limit has elapsed. This is normal, and does not mean RAP power mode is malfunctioning. The BCM enables the following functions in RAP Power Mode: The sunroof (internal to BCM - if equipped) - The right and left power rear windows (internal to BCM - if equipped) - Any class 2 module that functions in RAP power mode (that is not hard-wired), is controlled by the BCM via class 2 power mode messages. EXAMPLE: the radio works in RAP power mode due to the BCM allowing and controlling it. RAP is disabled when: The door is opened. - A low battery voltage is detected by the BCM. - The transition of ignition switch from OFF to ON or ACC. - 10 minutes have elapsed after the ignition was turned OFF. - There may be some functions of the vehicle that are hard-wired straight to the battery, these are the exceptions. The BCM monitors the ignition switch position, battery voltage and passenger compartment door status to determine whether RAP power mode should be enabled. If the ignition switch transitions from ON to OFF, the battery voltage is within the acceptable range and the passenger compartment doors are closed, the BCM enables RAP power mode. After the 10 minutes has elapsed, the BCM sends a class 2 message to the serial data network. This message commands the other modules to stop functioning, that are power moded by the BCM. RAP RELAY (IF EQUIPPED) The long base vehicles (GMT370), with third row seating, will have a RAP relay (RAP relay is also on the G/H Van). Due to this, the BCM will power/enable a relay. On the short based vehicles (GMT360), the RAP output only needs to drive the sunroof. The BCM is able to supply enough current to operate the sunroof by itself, so a relay is not needed. Although, on the GMT370/longbase vehicle, there are optional powered rear quarter vent windows, which are also enabled in RAP power mode. Refer to Retained Accessory Power (RAP) Schematics for the applicable schematics for RAP on both vehicle types. On the GMT370/longbase vehicle, the BCM is not able to supply enough current to both rear quarter vent windows and the sunroof at the same time (if equipped with both options). This is the purpose of the RAP relay. The BCM energizes the RAP relay coil, which allows a fused power supply to the sunroof and the rear quarter vent windows. Page 10731 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 8223 Defrost Actuator Page 810 Diagrams Engine Oil Level and Temperature Sensor Page 353 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 9793 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 11012 Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. To prevent a repeat occurrence of the above condition, Do Not return the vehicle to the customer without replacing the AIP seal if water intrusion was determined to be the cause. If water intrusion was determined to be the cause for the replacement of the spark plug(s) and/or coil(s), the AIP seal should be replaced. Installation of AIP Seal To prevent a reoccurrence, the revised AIP seal will redirect the rain water flow away from the engine cam cover area. The following repair information Page 1284 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P upper trim pad. 2. Remove the sun load sensor from the I/P upper trim pad by turning counter clockwise. 3. Disconnect the electrical connector from the sun load sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sun load sensor. 2. Install the sun load sensor to the I/P upper trim pad by turning clockwise. 3. Install the I/P upper trim pad. Specifications Wheel Bearing: Specifications Wheel Hub and Bearing Mounting Bolts 77 ft. lbs. Page 10527 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 11651 Glove Compartment Lock Cylinder: Service and Repair KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE The lock cylinder keyway is designed so that other model keys will not enter a current model lock cylinder. A single key is used for all locks on the vehicle. The key identification is obtained from the four-character key code stamped on the knockout portion of the key head. Knock the plugs out of the key head after code numbers have been recorded. The code list, available to owners of key cutting equipment from equipment suppliers, determines the lock combinations from the code numbers. CUTTING KEYS After the code has been determined from the code list or the key code diagram, perform the following steps: 1. Cut a blank key to the proper level of each of the tumbler positions. 2. Inspect the key operation in the lock cylinder. REPLACEMENT LOCK CYLINDERS New lock cylinders (except ignition lock cylinders) are available from the service parts warehouse with new lock cylinder locking bars. The tumblers are also available and must be assembled into the cylinder as recommended. For additional information, refer to the following. LOCK CYLINDER TUMBLER OPERATION All lock tumblers are shaped alike with the exception of the notched position on one side. As the key is inserted into the lock cylinder, the tumblers are lowered to the correct height so that notches on each tumbler are at the same level. When the notches on all 6 tumblers line up, 2 small springs push the side bar into the notches, allowing the cylinder to turn in the cylinder bore. Five types of tumblers are used in making the lock combinations, and each is coded and stamped with a number between 1 and 5. ASSEMBLING AND CODING IGNITION LOCK CYLINDERS TOOLS REQUIRED J 41340 Ignition Lock Holding Fixture 1. Determine the tumbler numbers/arrangement: 1.1. Place the tip of the key directly over the tip of the illustrated key. 1.2. Inspect that the diagram outlines the key. 1.3. Starting with position 1 (open end of cylinder), find and record the lowest level (tumbler number) that is visible. 1.4. Repeat the previous step for positions 2-10. Diagrams Mirror Switch, Driver Door Module (DDM) - C5 Page 101 Steps 8-12 Page 12139 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 2771 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 7054 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 3506 Abbreviations And Meanings Part 23 Page 9984 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 12450 Seat Cushion Bracket Replacement - Rear No. 1 - 1 SEAT CUSHION BRACKET REPLACEMENT - REAR NO. 1 (TRAILBLAZER, ENVOY, BRAVADA) REMOVAL PROCEDURE 1. Remove the rear seat cushion assembly from the vehicle. 2. Remove the 2 bolts securing the bracket assembly to the seat cushion. 3. Remove the bracket assembly from the seat cushion. INSTALLATION PROCEDURE Page 6203 Abbreviations And Meanings Part 2 Coupling Replacement - Antenna Inner Global Positioning System Antenna: Service and Repair Coupling Replacement - Antenna Inner COUPLING REPLACEMENT - ANTENNA INNER REMOVAL PROCEDURE 1. Disconnect the coaxial cable from the inner coupling of the mobile communication antenna (1). IMPORTANT: The adhesion promoter must be used to assure adequate bonding of the coupling. - To obtain maximum adhesion between the new cellular antenna couplings and the glass surface, the cellular antenna couplings and the glass must be kept dry and above 15°C (60°F) during the installation, and for 24 hours immediately following the installation. Otherwise the new couplings may not remain on the glass. - Do not attempt to reinstall the original couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Use a thin, wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling. NOTE: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. IMPORTANT: If the vehicle is equipped with diversity antennas, move the thin, wide-bladed plastic tool in the direction away from the antenna grid lines (2). INSTALLATION PROCEDURE 1. Clean the inside of the back glass with alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. 3. Apply Glass Adhesion Promoter GM P/N 12378555 (Canadian P/N 88901239) to the back glass in the area the antenna coupling is to be installed. Follow the Glass Adhesion Promoter instructions on the product label. Page 5751 16. Install the TCC PWM solenoid (1) to the control valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the transmission fluid indicator stop bracket bolt to 11 Nm (97 inch lbs.). 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 Shift solenoid (2) ^ The 2-3 Shift solenoid (3) ^ The pressure control solenoid 14) ^ The TCC PWM solenoid (5) ^ The 3-2 Shift solenoid (6) 20. Install the transmission oil pan and filter. 21. Lower the vehicle. 22. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. A/T - Oil Cooler Flushing Frequently Asked Questions Transmission Cooler: All Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Page 10534 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 5107 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 13140 Abbreviations And Meanings Part 12 Page 10138 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Heated Oxygen Sensor (HO2S) 1 Replacement Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 1 Replacement TOOLS REQUIRED J 39194-B Heated Oxygen Sensor Wrench REMOVAL PROCEDURE NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 1. Disconnect the heated oxygen sensor (HO2S) electrical connector (1). 2. Remove the HO2S (2) using a J 39194-B. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. INSTALLATION PROCEDURE IMPORTANT: Use special anti-seize compound on the heated oxygen sensor threads. The compound consists of graphite suspended in fluid and glass beads. The graphite burns away, but the glass beads remain, making the sensor easier to remove. New service sensors already have the compound applied to the threads. If you remove an oxygen sensor and if for any reason you must install the same oxygen sensor, apply the anti-seize compound to the threads before reinstallation. 1. Coat the threads of the heated oxygen sensor with the anti-seize compound P/N 5613695, or the equivalent if necessary. 2. Install the heated oxygen sensor (2) using a J 39194-B. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Page 8498 HVAC Control Module C1 Part 3 Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 4763 1. Install the air cleaner outlet resonator assembly (5) to the engine making sure of the following: - The crankcase ventilation hose (1) is connected to the valve cover port (2). - The air cleaner outlet resonator (5) is properly fit to the throttle body assembly. 2. Install the two air cleaner outlet resonator to engine bolts (4). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the resonator to engine bolts to 6 N.m (53 lb in). 3. Connect the fuel pressure regulator vacuum supply to the air cleaner outlet resonator. 4. Connect the air cleaner outlet duct to the air cleaner outlet resonator. 5. Connect the electrical connector to the intake air temperature (IAT) sensor (1). 6. Properly position the air cleaner outlet duct and air cleaner outlet resonator clamps (2). Tighten Tighten the clamps (2) to 4 N.m (35 lb in). Page 4169 Steps 6-9 Page 2784 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Recall 05V494000: Rear Door Latch Corrosion Rear Door Latch: Recalls Recall 05V494000: Rear Door Latch Corrosion MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Trailblazer EXT 2002-2003 GMC/Envoy XL 2002-2003 Isuzu/Ascender 2003 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V494000 MFG'S REPORT DATE: October 26, 2005 COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 98007 SUMMARY: Certain sport utility vehicles have a rear side closure latch that may not latch or unlatch due to corrosion caused by road splash, such as water and road salt. These vehicles are registered or sold in the following states: Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and The District of Columbia. CONSEQUENCE: If the door is not latched properly and it goes unnoticed, it may open while the vehicle is in motion. If an occupant fell out of the vehicle, personal injuries could occur. REMEDY: Dealers will install a seal along the lower part of the rocker panel to prevent intrusion of corrosive material, and inspect the rear side closure latches. Functional latches will be cleaned and lubricated. Non-functioning latches will be replaced. The recall is expected to begin during January 2006. Owners should contact Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or Isuzu at 1-800-255-6727. NOTES: GM recall No. 05077. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 4078 Page 4206 Heated Oxygen Sensor (HO2S) 1 Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 9922 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 906 10. With an upward motion, remove the BCM (1) from the rear electrical center. INSTALLATION PROCEDURE 1. Index the slots on the BCM (1) to the rear electrical center. 2. Using a downward motion, install the BCM to the rear electrical center. Page 11707 Trim Panel: Service and Repair Garnish Molding Replacement - Center Pillar Garnish Molding Replacement - Center Pillar Removal Procedure 1. Remove the front and rear door sill plates. 2. Move the seat to a forward position. 3. Release the 4 retaining clips that attach the garnish molding to the center pillar. 4. Disconnect the electrical connector from the temperature sensor, if equipped. 5. Remove the garnish molding from the vehicle. Installation Procedure 1. Position the garnish molding to the center pillar. 2. Connect the electrical connector to the temperature sensor, if equipped. 3. Index the positioning tabs on the garnish molding to the corresponding holes in the center pillar. 4. Seat the 4 garnish molding retaining tabs to the center pillar. 5. Return the seat to neutral position. 6. Install the front and rear door sill plates. Page 10849 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Air Cleaner Outlet Resonator Replacement Resonator: Service and Repair Air Cleaner Outlet Resonator Replacement REMOVAL PROCEDURE 1. Loosen the air cleaner outlet duct and air cleaner outlet resonator clamps (2). 2. Disconnect the electrical connector from the intake air temperature (IAT) sensor (1) . 3. Disconnect the air cleaner outlet duct from the air cleaner outlet resonator. 4. Disconnect the fuel pressure regulator vacuum supply from the air cleaner outlet resonator. 5. Remove the two air cleaner outlet resonator to engine bolts (4). 6. Disconnect the crankcase ventilation hose (1) from the valve cover port (2). 7. Remove the air cleaner outlet resonator assembly (5) from the engine. INSTALLATION PROCEDURE OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 13717 Miniwedge (Door Jamb Switch) - LR Page 14004 Locations Engine, Left Side Page 13050 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 6. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. 5. Access the I/P module connector through the glove box. Page 12629 Seat Adjuster Switch - Passenger (w/o Heat) Part 1 Page 227 Page 9175 Abbreviations And Meanings Part 8 Page 2743 Engine Oil Level And Temperature Sensor Specifications Ride Height Sensor: Specifications Air Spring Leveling Sensor to Frame Mounting Bolts 7 ft. lbs. Page 1053 Page 13390 1. Position the sensor to the trim pad. 2. In order to install the sensor to the trim pad, rotate the sensor clockwise 1/4 turn. 3. Position the trim pad to the upper portion of the instrument panel (IP). 4. Connect the electrical connector to the sensor. 5. Remove the shop rags from the windshield defrost vents. 6. Install the trim pad to the IP. 7. Install the windshield garnish moldings. Page 7087 C109 Page 9915 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 8269 Air Register: Service and Repair Instrument Panel - Center AIR OUTLET REPLACEMENT - INSTRUMENT PANEL - CENTER REMOVAL PROCEDURE 1. Remove the left closeout/insulator panel. 2. Remove the knee bolster trim panel. 3. Remove the instrument panel (I/P) cluster bezel, Chevrolet only. 4. Remove the radio. 5. Remove the 2 screws (1) from the bottom of the air outlet assembly. 6. Remove the air deflectors from the outlet. 7. Grasp and pull the outlet rearward from the I/P. Diagrams Hood Ajar Switch (Export) Page 6894 Abbreviations And Meanings Part 9 Page 3578 Powertrain Control Module (PCM) C1 Part 4 Page 10711 3. Install the quick connector to the VCIM. 4. Install the remaining electrical connectors to the VCIM. 5. Install the VCIM (1) to the bracket. 6. Ensure the retaining tab (1) is fully seated. Page 4522 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the fuel pressure service connection cap. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Install the fuel tank shield if removed. OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 11311 Disclaimer Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 6302 9. Remove the retaining clips from the brake rotor. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J 42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. Important: if the brake rotor is not going to be replaced but just removed from the front hub, mark the relationship of the brake rotor and a wheel stud. 10. Remove the front brake rotor from the wheel hub. 11. Using the J 42450-A, clean the brake rotor contact area on the front hub. Installation Procedure Important: Ensure that the relationship marks on the brake rotor and the wheel stud are aligned before installing the brake rotor. Page 7826 1. Install the lower ball joint and J9519-E, J41435, and J45105-2 to the lower control arm. 2. Install the lower ball joint to the lower control arm using J9519-E, J41435, and J45105-2. 3. Remove J9519-E, J41435, and J45105-2 from the lower control arm. 4. Install J9519-E and J45105-1 to the lower ball joint. 5. Flare the lower ball joint flange using J9519-E and J45105-1. 6. Remove J9519-E and J45105-1 from the lower ball joint. 7. Install the steering knuckle with wheel hub and bearing attached. Install the tire and wheel. 9. Lower the vehicle. 10. Check the front wheel alignment. Page 5662 Transmission Mount: Service and Repair Transmission Mount Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a suitable jack. 3. Remove the nuts securing the transmission mount to the transmission support. 4. Remove the transmission support from the vehicle. 5. Remove the transmission mount bolts (1, 2). Page 11994 Bulletin No.: 03-08-111-002G Date: December 21, 2007 TECHNICAL Subject: Paint Chipping Behind Front wheels/Front of Rear Wheels Damaged Lower Door/Cladding and Rocker Panels (Repaint Damaged Area Install Assist Step) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2008 Chevrolet TrailBlazer 2006-2007 Chevrolet TrailBlazer 55 2002-2006 GMC Envoy XL 2002-2008 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X Attention: Implementation of this Service Bulletin requires case-by-case review and approval by your District Service Manager (DVM) (U.S.) or District Service Manager (DSM) (Canada) PRIOR to the performance of any repairs. Supercede: This bulletin is being revised to add the 2008 model year for TrailBlazer Envoy and Saab 9-7X models and change the refinish materials reference. Please discard Corporate Bulletin Number 03-08-111-002F (Section 08 - Body and Accessories). Condition Some customers may comment that the paint is chipped just behind the front wheels as well as just in front of the rear wheels. Some customers may also comment about damage to the lower door/cladding and rocker panels. Cause The rocker and lower door areas may be damaged by road debris thrown up by the tires at highway speeds. Correction It may be necessary to perform the following repair in order to meet customer expectations and gain their product satisfaction. Follow the manufacturers specifications for repainting the lower door/cladding and rocker panel and refer to the 2008 GMWI5406 GM Globally Approved Refinish Materials information for the type of paint and refinish materials to use. The refinish materials information is now online at the GMGOODWRENCH WEB SITE*. Printed books have been discontinued. To access the site follow these steps: Go to www.gmgoodwrench.com. Click on For Body Shops & Services link at the bottom of the page. Click on GM Technical Repair Information. Click on Paint Shop tab. Select the applicable downloadable link of the GM Approved Refinish Materials Guide. *In Canada the 2008 GM Approved Refinish Materials information is also available on the GM infoNET under the Service and Body tab. For all of the above vehicles except TrailBlazer SS install the assist step. For the TrailBlazer SS install a Protector Kit P/N 15783524. Instructions are included in the kit. Page 12479 Tighten the rear seat cushion trim panel screws to 2 N.m (18 lb in). 2. Install the seat cover J-strips (1) to the seat cushion trim panel (2). 3. Install the two bolts (2) securing the support (1) to the seat cushion trim panel. Tighten the rear seat support bolts to 35 N.m (26 lb ft). 4. Install the rear seat bracket with the four mounting nuts (2). Tighten the rear seat bracket mounting nuts to 25 N.m (18 lb ft). 5. Install the rear seat bracket trim covers (1). 6. Install the seat in the vehicle. Seat Cushion Pull Strap Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada) Seat Cushion Pull Strap Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada) Removal Procedure 1. Remove the rear seat cushion assembly from the vehicle. 2. Remove the rear-seat cushion cover and the pad. 3. Remove the strap (1) from the rear seat cushion latch (2). Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 4665 1. Lubricate the new lower injector O-ring seals (4) with clean engine oil. 2. Install the new O-ring seals (4) on the spray tip end of each injector (3). 3. Install the fuel rail assembly. 4. Install the fuel rail attaching bolts. NOTE: Refer to the Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (89 lb in). Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 3879 Page 6192 Conversion - English/Metric Part 1 Page 7991 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Shock Absorber Replacement Shock Absorber Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: The rear axle must not be allowed to hang freely while servicing rear suspension components. Not supporting the rear axle will result in damage to the upper control arm and/or to the air suspension components. 2. Support the rear axle. 3. Remove the shock absorber upper mounting bolt. 4. Remove the shock absorber lower mounting bolt. 5. Remove the shock absorber from the vehicle. Installation Procedure Page 6859 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Diagrams Hood Ajar Switch (Export) Page 12934 Abbreviations And Meanings Part 23 Page 4962 Automatic Transmission Shift Lock Control Solenoid Page 3663 Oil Pressure Sensor: Diagrams Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Page 7321 Application Table Part 3 Page 4083 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 7142 8. Release the tabs that retain the junction block to the block base. 9. Remove the junction block from the block base. 10. Disconnect the instrument panel harness connector (1) from the junction block. 11. Disconnect the mobile telephone harness connector (1) from the junction block. Page 7226 Page 332 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 822 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 3535 3. Connect the 24-way gray electrical connector (1) to the BCM. 4. Connect the 32-way tan electrical connector (2) to the BCM. 5. Connect the 40-way body wiring extension (1) to the BCM. 6. Engage the sliding latch fastening the BCM to the rear electrical center. Slide the latch outboard until the locking tab (1) is fully seated. Page 4260 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 544 Electrical - SES Lamp ON/DTC's P0480/P0526/P1481/P1484 Radiator Cooling Fan Motor: All Technical Service Bulletins Electrical - SES Lamp ON/DTC's P0480/P0526/P1481/P1484 Bulletin No.: 05-06-02-012B Date: October 19, 2006 TECHNICAL Subject: Service Engine Soon (SES) or Check Engine Light On, DTC P0480/P0526/P1481/P1484 Set (Replace Engine Cooling Fan Wiring Harness) Models: 2004-2006 Buick Rainier 2002-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2006 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2005-2006 GMC Envoy Denali, Envoy XL Denali 2002-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Supercede: This bulletin is being revised to add DTC P1484. Please discard Corporate Bulletin Number 05-06-02-012A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the Service Engine Soon (SES) or Check Engine light is illuminated. This condition may be intermittent and upon investigation, the technician may find either DTC P0480, P0526, P1481 or P1484 set. Cause This condition may be caused by the cooling fan harness chaffing against the plastic guide it routes through. This contact may damage the insulation of the wires enclosed in that harness. Correction Replace the engine cooling fan harness using the procedure listed below. Remove the cooling fan. Refer to the Cooling Fan and Shroud Replacement procedure in the Engine Cooling sub-section of SI. Place the cooling fan assembly on a bench. Disconnect the harness electrical connector from the cooling fan clutch. Remove the harness from the plastic guide while feeding the wires out of the slot. Before installing the new harness, wrap the affected area on the wires with electrical tape to keep the protective sleeve in place. Be sure to keep the tape Locations Hazard Switch Page 5676 Vehicle Speed Sensor Assembly Connector, Wiring Harness Side Page 463 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 2373 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 5574 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7678 2. Install the power steering pump. 3. Install the power steering pump mounting bolts. Tighten the power steering pump mounting bolts to 25 Nm (18 ft. lbs.). 4. Install the power steering cooler hose (2) to the power steering pump. 5. Install the power steering pressure hose (1) to the power steering pump. Tighten the power steering pressure hose to 25 Nm (18 ft. lbs.). 6. Remove the drain pan from under the vehicle. 7. Install me drive belt. 8. Install the air cleaner assembly. 9. Install the radiator air intake baffle. 10. Bleed the power steering system. 11. Inspect the power steering system for leaks and the hoses for clearance away from the frame and other components. Page 2882 Page 10358 Abbreviations And Meanings Part 11 Page 967 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 3 Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 4576 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Locations Rain Sensor: Locations Inside Rearview Mirror Page 3042 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the fuel pressure service connection cap. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Install the fuel tank shield if removed. Audio Amplifier C1 (With RPO Code UQA) Amplifier: Diagrams Audio Amplifier C1 (With RPO Code UQA) Audio Amplifier C1 (With RPO Code UQA) Part 1 Service and Repair Expansion Valve: Service and Repair THERMAL EXPANSION VALVE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the evaporator core-auxiliary. 2. Remove the foam insulators (3) from the evaporator core-auxiliary lines. 3. Remove the foam insulators from the thermal expansion valve-auxiliary (4). 4. Using a back up wrench loosen the flare nuts from the thermal expansion valve-auxiliary. 5. Remove the auxiliary thermal expansion valve sensing bulb and retaining clip from the evaporator core-auxiliary lines. 6. Remove the thermal expansion valve-auxiliary from the evaporator core-auxiliary. 7. Remove and discard the O-ring seals from the evaporator core-auxiliary. Cap or tape the lines to prevent contamination of the evaporator core-auxiliary. IMPORTANT:Cap or tape the open A/C refrigerant lines immediately. INSTALLATION PROCEDURE 1. Remove the cap or tape from the evaporator core-auxiliary lines. 2. Install the new O-ring. 3. Install the thermal expansion valve-auxiliary onto the evaporator core-auxiliary lines. 4. Using a back up wrench, install the flare nuts from the evaporator core-auxiliary lines to the thermal expansion valve-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the nuts to .5 N.m (44 lb in). Page 12714 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Page 11106 12. Install the water deflector. 13. Install the speaker. 14. Install the door trim panel. Page 564 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 12197 Front Passenger Door Module (FPDM) - C2 Part 1 Diagrams Cellular Microphone A/T, Exhaust - Rattling Noise From Under the Vehicle Fluid Line/Hose: Customer Interest A/T, Exhaust - Rattling Noise From Under the Vehicle Bulletin No.: 04-07-30-002 Date: January 20, 2004 TECHNICAL Subject: Rattle Type Noise Coming From Under the Vehicle (Reposition Transmission Oil Cooler Lines) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2004 GMC Envoy, Envoy XL 2002-2004 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on a rattle type noise coming from under the vehicle. Cause This condition may be caused by one of the transmission oil cooler lines contacting the exhaust catalytic converter. Correction Raise the vehicle and carefully reposition the transmission oil cooler line(s) to provide 10 mm (0.393 in) clearance between the exhaust catalytic converter and the line. Replace the transmission oil cooler line if any damage is present. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1658 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 1128 Seat Adjuster Switch - Passenger (w/o Heat) Part 2 Page 12893 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Instruments - Erratic Speedometer Operation Engine Control Module: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 9128 Page 2302 Vehicle Lifting Points The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: - Beneath the lower control arms, inboard from the shock absorber mounts - Beneath the center of the front crossmember Page 3837 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils Page 6492 10. Install the park brake retaining bracket bolt in the frame. ^ Tighten park brake cable retaining bracket bolt to 20 Nm (15 ft. lbs.). 11. Install the park brake cable to the park brake cable retainers, left rear shown. 12. Install the shield for the fuel tank. Page 5193 11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. 12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. 13. Install the 1-2 accumulator inner and outer springs to the 1-2 accumulator cover. 14. Install the 1-2 accumulator piston onto the pin in the 1-2 accumulator cover. Ensure that the piston legs face the accumulator cover. Page 2081 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Page 8800 Ambient Temperature Sensor / Switch HVAC: Diagrams Air Temperature Sensor-Lower Left Page 6786 Various symbols in order to describe different service operations. Page 13266 Abbreviations And Meanings Part 4 Headliner Replacement (TrailBlazer EXT, Envoy XL) Headliner: Service and Repair Headliner Replacement (TrailBlazer EXT, Envoy XL) Headliner Replacement (TrailBlazer EXT, Envoy XL) Caution: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure to do so could result in personal injury. Removal Procedure 1. Ensure the ignition switch is in the LOCK position. 2. Remove the cargo net, if equipped. 3. Remove the luggage/cargo shelf assembly, if equipped. 4. Remove the right sound insulator panel. 5. Remove the front door sill plates. 6. Remove the rear door sill plates. Notice: Remove the headliner and the headliner harness as an assembly. Do NOT cut or splice the headliner harness. Cutting or splicing the harness may damage the coax cable, resulting in poor radio performance. 7. Remove the center pillar trim panels. 8. Remove the windshield garnish moldings. 9. Remove the front and rear overhead console, If equipped. 10. Remove the video display, if equipped. 11. Remove the sunshades from the headliner. 12. Remove the sunshade retainer clips. 13. Remove the third row seats. 14. Remove the second row seats. 15. Remove the left/right front body side window garnish molding. 16. Remove the left/right rear body side window garnish molding. 17. Remove the lift gate door sill plate. 18. Remove the left rear quarter lower trim panel. 19. Remove the right rear quarter lower trim panel. 20. Remove the bolts from the cargo tie-down loops. 21. Remove the nut (1), securing the stowage jack carrier to the wheelhouse panel. 22. Loosen the three bolts that secure the jack carrier to the vehicle. 23. Remove the carpet from around the wheel stud. 24. Remove the body electrical block. Locations Connector C201 HVAC System - Manual Blower Motor Switch: Service and Repair HVAC System - Manual FRONT AUXILIARY BLOWER MOTOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Press downward and to the right on the front auxiliary blower motor switch. 2. Remove the front auxiliary blower motor switch from the console. 3. Disconnect the electrical connector from the front auxiliary blower motor switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the front auxiliary blower motor switch. 2. Install the front auxiliary blower motor switch to console. 3. Press the front auxiliary blower motor switch into the console. Page 5212 4. Tighten the bolt in order to compress the servo cover. 5. Install the servo cover retaining ring. 6. Remove the J 29714-A from the oil pan flange. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the transmission oil pan bolt. ^ Tighten the bolt to 11 Nm (97 inch lbs.). 8. Install the heat shield if equipped. 9. Install the exhaust pipe assembly. 10. Install the transmission support. 11. Remove the transmission jack. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Page 13650 8. If replacing the dome lamp bulb (1), remove the dome lamp bulb from the socket. INSTALLATION PROCEDURE 1. If replacing the dome lamp bulb (1), install the dome lamp bulb to the socket. 2. If replacing the reading lamp bulb (1), install the reading lamp bulb to the socket. 3. Install the reflector (2) to the dome lamp, ensuring the retaining tabs are fully seated. Page 4367 Engine Control Module: Description and Operation POWERTRAIN CONTROL MODULE (PCM) The PCM verifies that the password received from the theft deterrent control module via the serial data circuit is correct. The PCM can learn only one fuel continue password. If the fuel continue password is correct, the PCM enables the starting and fuel delivery systems. The PCM disables the starting and fuel delivery systems if any of the following conditions occur: - The fuel continue password is incorrect. - The fuel disable password is sent by the theft deterrent control module. - No passwords are received - there is no communication with the theft deterrent control module. The powertrain control module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. The PCM controls all ignition system functions, and constantly corrects the spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Page 5504 6. Remove the 1-2 and 2-3 Shift solenoid retainers. 7. Remove the 1-2 and 2-3 Shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Page 6225 Abbreviations And Meanings Part 24 Page 10218 Labor Time Information Page 4246 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Specifications Brake Pedal Assy: Specifications Brake Pedal Pivot Bolt 19 ft. lbs. Brake Pedal Maximum Travel See Note Specification with 445 N (100 lbs) of force applied to the brake pedal, the ignition OFF, and the brake booster power reserve depleted. Page 8867 Low Pressure Sensor / Switch: Description and Operation HVAC System - Automatic HVAC SYSTEM - AUTOMATIC A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 12 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 124 kPa (18 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275 kPa (40 psi). This enables the A/C compressor to turn back ON. Page 14010 Page 6144 Brake Bleeding: Service and Repair Pressure Bleeding Procedure Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder- loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 35589-A. 8. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Page 9429 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). A/T - Key Will Not Release From Ignition Lock Cylinder Ignition Switch Lock Cylinder: All Technical Service Bulletins A/T - Key Will Not Release From Ignition Lock Cylinder Bulletin No.: 05-07-30-021B Date: October 04, 2007 TECHNICAL Subject: Ignition Key Will Not Remove From Ignition Lock Cylinder (Reposition Shifter Boot) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2003-2004 Oldsmobile Bravada Supercede: This bulletin is being revised to include the 2008 model year. Please discard Corporate Bulletin Number 05-07-30-021A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that they are unable to remove the ignition key from the ignition cylinder. Cause The shifter boot may be caught/trapped in the shifter assembly mechanism. Correction Inspect the shifter boot for being caught/trapped in the shifter assembly. If the shifter boot is NOT caught/trapped in the shift assembly, refer to Ignition Key Cannot Be Removed from the Ignition Lock Cylinder in SI. If the shifter boot IS caught/trapped in the shifter assembly, continue with the next step. DO NOT replace the complete shifter assembly for this condition. ONLY replace the shifter boot/handle if damaged by shifter assembly. Reposition the shifter boot so that it is not caught/trapped in the shifter assembly. Warranty Information Page 13123 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 5185 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Page 4184 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE 1. Install the knock sensor (1 or 2) and the bolt (3). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 13940 Abbreviations And Meanings Part 10 Color Compatibility Guide (Paint Codes) Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Page 8819 Blower Motor Switch: Diagrams Blower Motor Switch - Front Auxiliary (Body Type VIN 6) Page 6698 Abbreviations And Meanings Part 20 Page 13432 Please follow the instructions on the Claim Form to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Service Procedure 1. Open the rear liftgate. 2. Remove the two screws that attach both the left and right tail lamp assemblies and remove the lamps from the body. 3. Inspect the part number on both the left and right tail lamp circuit boards. Chevrolet -- New P/N 16532713 Chevrolet Export -- New P/N Page 11342 Power Trunk / Liftgate Control Module: Diagrams Endgate Module (EGM) Endgate Module (EGM) C1 (XUV) Page 9134 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Entertainment System - DVD Monitor Display Inoperative DVD Player: All Technical Service Bulletins Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 12822 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 8366 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 12389 Seat Lumbar Motors And Position Sensors Assembly - Driver Part 1 Page 13674 Page 5222 Disclaimer Page 9173 Abbreviations And Meanings Part 6 Page 8259 Air Duct: Service and Repair Air Outlet Duct Replacement - Floor, LH AIR OUTLET DUCT REPLACEMENT - FLOOR, LH REMOVAL PROCEDURE 1. Remove the LH lower closeout/insulator panel. 2. Remove the push pin (2) retaining the floor air outlet duct (1) to the heater module. 3. Remove the floor duct (1). INSTALLATION PROCEDURE 1. Install the floor air outlet duct (1) into position. 2. Install the floor air outlet duct retaining push pin (2). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to .....1.9 N.m (17 lb in). 3. Install the LH lower closeout/insulator panel. Replacement - Floor, RH AIR OUTLET DUCT REPLACEMENT - FLOOR, RH Page 7246 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 9621 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 8074 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 2194 Application Table Part 1 Page 9820 Abbreviations And Meanings Part 12 Page 5485 Electronic Components Page 10142 Circuit/System Testing Component Testing Page 12033 WA8555/41 - WA8555/41 Locations Door Switch: Locations Door Jamb Switch, Miniwedge - LR Specifications Idler Pulley: Specifications Drive Belt Idler Pulley Bolt 37 ft. lbs. Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 971 1. Remove any dirt, grease, etc. from the mounting surface. 2. Install the SDM horizontally to the vehicle. 3. Point the arrow on the SDM towards the front of the vehicle. 4. Install the nuts that retain the SDM to the floor panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 12 N.m (106 lb in). 5. Connect the electrical connectors (2) to the SDM (1). 6. Return the carpet to the fully installed position. 7. Install the console mounting bracket to the floor panel. 8. Install the floor console. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 8. Page 5013 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Specifications Ride Height Sensor: Specifications Air Spring Leveling Sensor to Frame Mounting Bolts 7 ft. lbs. Page 7675 3. Install the power steering pump pulley (1) flush against the end of the power steering pump shaft (2), with an allowable variance of 0.25 mm (0.010 inch). 4. Install the drive belt. 5. Install the radiator air intake baffle. Page 2359 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 6857 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 131 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 12456 3. Remove the seat latch bezels. 4. Use the J 36796 to remove the push pins (1) on the underside of the seat bottom, in order to start the seat cushion removal procedure. 5. Fold the carpet back in order to release the J-strips that retain the cover to the seat pan. 6. Starting at either forward corner, compress the foam and partially remove the seat cover assembly from the seat pan. 7. Remove the cover from the cushion by separating the retaining strips. IMPORTANT: When separating the seat cover retaining strips, do not pull the adhesive-backed strip from the seat pad. 8. Separate and remove the cushion and cover assembly from the seat pan. 9. Release the reinforcement bar from the hog-rings. 10. Remove the cover from the cushion. Locations Engine, Left Front Page 12151 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 8962 Inflatable Restraint Side Impact Module-Right Page 689 Sunroof Harness With Headliner Removed Page 10956 and Accessories). Condition Some customers may comment that the front fascia is wavy under the grille or under the front turn signals. Refer to the illustration above. Correction 1. Remove the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. 2. Remove the impact bar from the front fascia. 3. Remove the hot melt on the top of the impact bar. 4. Clean and scuff the impact bar with a scotch bright pad. 5. Apply a coating of GM Adhesion Promoter, P/N 12378462 (Canadian P/N 10953554), to the top surface of the impact bar and let dry. 6. Install 3M Dual Lock, P/N 06463, to the impact bar as shown in the illustration above. 7. Clean the fascia and apply the Adhesion Promoter to the fascia. 8. Install the impact bar to the fascia. 9. Install the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. Parts Information Warranty Information Page 6668 Various symbols in order to describe different service operations. Page 12919 Abbreviations And Meanings Part 8 Page 4098 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. Page 324 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 2106 IMPORTANT:When adding to, or changing the engine oil, use ONLY oils of the proper quality. In countries other than the United States and Canada, it may be difficult to find engine oils that display the API STARBURST symbol certifying the oil is for use in gasoline engines. If you are unable to find engine oils displaying the API STARBURST symbol, use engine oils that meet API Service SJ and/or ACEA A1-96, ACEA A2-96, or ACEA A3-96 requirements as shown in the chart. Lighting - Center Mounted Stop Lamp Applique loose Center Mounted Brake Lamp: All Technical Service Bulletins Lighting - Center Mounted Stop Lamp Applique loose Bulletin No.: 05-08-111-006B Date: April 10, 2006 TECHNICAL Subject: Rear Center High Mounted Stop Lamp (CHMSL) Applique Sealing Strip Loose (Repair or Replace Sealing Strip) Models: 2003-2006 Chevrolet TrailBlazer EXT 2003-2006 GMC Envoy XL Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 05-08-111-006A (Section 08 - Body and Accessories). Condition Some customers may comment that the sealing strip has come loose from the CHMSL applique. Correction If the seal is not damaged, the seal can be cleaned and reinstalled with some weatherstrip adhesive. If the seal is damaged or missing, replace the seal with the applicable seal part number below. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 10399 Alarm Module: Description and Operation THEFT DETERRENT CONTROL MODULE Vehicles with steering column mounted ignition switches have the exciter integral with the theft deterrent control module which is located within the steering column. Vehicles with instrument panel mounted ignition switches have exciter modules separate from the theft deterrent control module with the vehicle wiring harness connecting the two. The theft deterrent control module for vehicles with instrument panel mounted ignition switches is located within the instrument panel. The theft deterrent control module can learn up to ten keys (transponder values). The theft deterrent control module uses the following inputs, battery voltage, ignition switched voltage and ground circuit. The theft deterrent control module uses the following outputs, password exchange with the PCM, fuel enable/disable via the serial data circuit. When an ignition key is inserted into the ignition lock cylinder and the ignition is switched ON, the transponder embedded in the head of the key is energized by the exciter coils surrounding the ignition lock cylinder. The energized transponder transmits a signal that contains its unique value, which is received by the theft deterrent control module. The theft deterrent control module then compares this value to a value stored in memory, learned key code. If the value is correct the theft deterrent control module sends a random generated number to the transponder, this is called a challenge. Both the transponder and the theft deterrent control module perform a calculation on the challenge. The theft deterrent control module then performs one of the following functions: - If both the transponder value and the calculation to the challenge are correct, the theft deterrent control module will send the fuel continue password to the PCM via the serial data circuit. - If either the transponders unique value or the calculation to the challenge is incorrect the theft deterrent control module will send the fuel disable password to the PCM via the serial data circuit. - If the theft deterrent control module is unable to measure the ignition key transponder value for one second due to a damaged or missing pellet or a damaged exciter, the theft deterrent control module will send the fuel disable password to the PCM via the serial data circuit. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 6791 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 6313 5. Install the rear brake rotor. 6. Install the brake caliper and bracket assembly. 7. Install the park brake cable to the rear brake caliper. 8. Adjust the park brake shoe. 9. Install the tire and wheel assembly. 10. Lower the vehicle. Refer to Vehicle Lifting. Page 9142 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 3921 Abbreviations And Meanings Part 8 Emissions - DTC P0440/P0455/P0442 (EVAP) Diagnostics Fuel Filler Neck: All Technical Service Bulletins Emissions - DTC P0440/P0455/P0442 (EVAP) Diagnostics Bulletin No.: 05-06-04-014A Date: March 21, 2005 INFORMATION Subject: Diagnostic Aids for Diagnostic Trouble Codes P0440, P0455 and/or P0442 - Evaporative Emission (EVAP) System Leak Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer Models 2002-2004 GMC Envoy Models 2002-2004 Oldsmobile Bravada with 83 Liter (22 Gallon) or 96 Liter (25 Gallon) Fuel Tanks Supercede: This bulletin is being revised to remove the 2005 model year. Please discard Corporate Bulletin Number 05-06-04-014 (Section 06 - Engine/Propulsion System). This bulletin is being published to aid technicians in the diagnosis of DTCs P0440, P0455 and/or P0442. It is possible that a fracture as small as 0.508 mm (0.020 in) may be found in the fuel tank filler neck, causing a DTC P0440, P0455 and/or P0442 to set. Due to the location above the liquid fuel level, this small fracture will not cause a visible fluid leak. The technician should pay particular attention to the fuel tank filler neck area while performing the smoke test outlined in SI. Refer to the appropriate diagnostic information for P0440, P0455 and/or P0442 in SI. When performing the smoke test outlined in SI, it may be necessary for the technician to manipulate the fuel tank filler neck in order to see smoke escaping from this minute fracture. Disclaimer Page 3835 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................. AC 41-981 Page 5178 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Page 3538 10. With an upward motion, disconnect the body wiring extension (1) from the rear electrical center. 11. Remove the body wiring extension from the vehicle. INSTALLATION PROCEDURE 1. Using a downward motion, install the body wiring extension (1) to the rear electrical center. IMPORTANT: Ensure the sliding latch is fully extended before connecting the body wiring extension to the rear electrical center. Page 6420 Page 6797 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 2798 Metric Prevailing Torque Fastener Minimum Torque Development Part 1 Page 9928 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. A/C - Revised Mode Actuator Replacement Procedure Air Door Actuator / Motor: Technical Service Bulletins A/C - Revised Mode Actuator Replacement Procedure Bulletin No.: 03-01-39-013 Date: November 07, 2003 SERVICE MANUAL UPDATE Subject: Revised Mode Actuator Replacement Procedure Models: 2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 GMC Envoy, Envoy XL 2003 Oldsmobile Bravada 2003 Isuzu Ascender This bulletin is being issued to revise the Mode Actuator Replacement Procedure in the HVAC Systems with A/C - Automatic sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Mode Actuator Replacement Removal Procedure 1. Remove the left floor air outlet duct. Refer to Air Outlet Duct Replacement - Floor, LH in Heating, Ventilation, and Air Conditioning. 2. Disconnect the electrical connector from the mode actuator. 3. Remove the screws from the mode actuator (3). 4. Remove the mode actuator. Installation Procedure Page 18 Instruments - Erratic Speedometer Operation Ground Strap: All Technical Service Bulletins Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 12635 1. Remove the 3 screws that retain the switch bezel to the seat. 2. Partially remove the switch bezel from the seat. 3. Remove the seat switches from the switch bezel by releasing the retaining tabs. 4. Remove the lumbar switch from the switch bezel by releasing the retaining tabs. 5. Remove the switch bezel from the seat. INSTALLATION PROCEDURE 1. Install the lumbar switch to the switch bezel, verifying that the retaining tabs are fully seated. Page 4513 5. Remove the 2 resonator to engine bolts (4) from the air cleaner outlet resonator (5). 6. Lift up the front of the air cleaner outlet resonator (2). 7. Disconnect the crankcase clean air hose from the valve cover port. 8. Disconnect the crankcase clean air hose from the air cleaner outlet resonator (2). Installation Procedure Page 2626 5. Connect the ignition control module electrical connectors. 6. Install the fuel injector electrical connectors. 7. Install the engine electrical harness housing (1). 8. Install the A/C line bracket to the oil level indicator tube stud and secure the bracket with the nut. Tighten the A/C line bracket nut to 7 Nm (62 inch lbs.). 9. Install the engine lift bracket and secure the lift hook with the bolts. Tighten the lift bracket bolts to 50 Nm (37 ft. lbs.). 10. Install the A/C line bracket to the engine lift bracket and secure the A/C bracket with the bolt. Tighten the A/C bracket bolt to 10 Nm (89 inch lbs.). 11. Install the intake manifold. 12. Recharge the A/C system. Page 2276 Application Table Part 2 Page 10545 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 667 Memory Seat Module - Passenger C3 Part 1 Page 6252 10. Remove the brake caliper mounting bracket. 11. Remove the guide pin seals from the brake caliper mounting bracket. 12. Inspect the brake rotor. Installation Procedure 1. Install the guide pin seals on the mounting bracket. 2. If the guide pins and brake pad retaining clips are to be reused, use denatured alcohol to clean them. 3. Dry the brake guide pins and brake pad retaining clips with non-lubricated, filtered air. Page 2637 12. Install the spark plugs. 13. Install the camshaft cover. Page 2565 Page 11624 Removal Procedure 1. Remove the 2 screws that retain the console to the roof panel. 2. Release the front retaining tabs. 3. Lower the console and disconnect the electrical connectors as needed. 4. Remove the console from the vehicle 5. If replacing the console, remove the garage door opener if equipped. Refer to Garage Door Opener Replacement in Garage Door Opener. 6. If replacing the console, remove the OnStar (R) microphone if equipped. Refer to OnStar Microphone Replacement in Cellular Communication. 7. If replacing the console, remove the personal message player/recorder if equipped. Refer to Personal Message Player/Recorder Replacement in Entertainment. 8. If replacing the console, remove the power sunroof switch if equipped. Refer to Sunroof Switch Replacement in Roof. 9. If replacing the console, remove the noise cancellation microphone if equipped. Refer to Microphone Replacement - Radio Volume Compensator Interior in Roof. Installation Procedure 1. If replacing the console, install the noise cancellation microphone if equipped. Refer to Microphone Replacement - Radio Volume Compensator Interior in Roof. 2. If replacing the console, install the power sunroof switch if equipped. Refer to Sunroof Switch Replacement in Roof. 3. If replacing the console, install the personal message player/recorder if equipped. Refer to Personal Message Player/Recorder Replacement in Entertainment. 4. If replacing the console, install the OnStar (R) microphone if equipped. Refer to OnStar Microphone Replacement in Cellular Communication. 5. If replacing the console, install the garage door opener if equipped. Refer to Garage Door Opener Replacement in Garage Door Opener. 6. Position the console to the roof panel. 7. Connect the electrical connectors as needed. 8. Seat the front retaining tabs. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the 2 screws retaining the console to the roof panel. Tighten the screws to 1.2 N.m (10 lb in). Overhead Console Replacement - Rear Overhead Console Replacement - Rear Removal Procedure Page 10875 Abbreviations And Meanings Part 11 Page 10996 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 7009 9. Install the 3 bolts (1) that retain the junction block to the block base. Tighten Tighten the 3 bolts to 3.5 N.m (31 lb in). 10. Install the BCM to the rear electrical center. 11. Install the battery feed terminal nut (2) to the junction block. Tighten Tighten the battery feed terminal nut to 10 N.m (88 lb in). 12. Install the rear electrical center cover. 13. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a passenger position. 14. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 15. Connect the battery negative cable. Page 4410 Fuel Tank Pressure (FTP) Sensor Page 12462 Seat Cushion Panel Replacement - Rear No. 2 SEAT CUSHION PANEL REPLACEMENT - REAR NO. 2 REMOVAL PROCEDURE 1. Remove the two rear seat cushion bolts (2) securing the rear seat cushion assembly (1) to the seat latch rod (3). 2. Remove the seat cushion assembly. 3. Remove the pull handle (1). 4. Remove the J-strips (2) securing the seat cushion cover to the seat cushion panel. 5. Remove the seat cushion panel from the pad and cover. INSTALLATION PROCEDURE Page 8322 34. Install the coolant bypass valve to its original location and secure with a nut. 35. Connect the other end of the new hose from step 29 to the outlet port of the auxiliary heater pump. 36. Connect the vacuum hose to the coolant bypass valve. 37. Connect the coolant bypass valve hose to the auxiliary rear heater line. 38. Install the heater hose quick connect retainers to the heater core pipes. 39. Connect the remaining two hoses to the heater core. 40. Install the new auxiliary heater pump wiring harness to the vehicle. Page 10005 Specifications Camshaft Gear/Sprocket: Specifications Exhaust Camshaft Actuator Bolt First pass 18 ft. lbs. Second pass 135° Intake Camshaft Sprocket Bolt First pass 15 ft.lbs. Second Pass 100° Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 2176 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom right of the door. Zone 7 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the CPA from the LF side impact module yellow 2-way connector (1) located under the driver seat. 6. Disconnect the LF side impact module yellow 2-way connector (1) located under the driver seat. Zone 8 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. 5. Access the I/P module connector through the glove box. Page 3499 Abbreviations And Meanings Part 16 Locations Engine, Right Front Page 7052 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 665 Memory Seat Module - Passenger C1 Page 4848 ^ Install the camshaft position actuator solenoid (2) and bolt (3). Tighten Tighten the bolt to 10 N.m (89 lb in). ^ Connect the camshaft position actuator solenoid electrical connector. ^ Install the power steering pump and bolts. ^ Install the drive belt. Knock Sensor (KS) 1 Front Knock Sensor (KS) 1 Front Page 13081 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 1719 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 8249 NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb in). 4. Install the air outlet duct to the console. 5. Install the screw to the air outlet duct. Tighten Tighten the screw to 1.9 N.m (17 lb in). 6. Install the console. Recirculation Actuator RECIRCULATION ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module assembly. 2. Remove the air inlet assembly screws. 3. Remove the air inlet assembly. 4. Remove the recirculation actuator screws. 5. Remove the electrical connector from the recirculation actuator. 6. Remove the recirculation actuator. INSTALLATION PROCEDURE 1. Install the recirculation actuator. 2. Install the screws to the recirculation actuator. NOTE: Refer to Fastener Notice in Service Precautions. Page 1776 Power Window Switch: Service and Repair Quarter Window Replacement Quarter Window Replacement Tools Required * J 39032 Stationary Glass Removal Tool * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Caution: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury. Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Open the liftgate. 2. Remove the upper quarter trim. Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: Keep the cutting edge of the tool against the window. Do this from inside the vehicle. 3. This will allow the urethane adhesive to be separated from the window. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. * Use J 39032 or equivalent in order to remove the window. 4. If the original reveal molding on the quarter window is damaged it must be replaced. 5. With the aid of an assistant, remove the quarter window from the opening. Installation Procedure 1. Install a stationary window into the opening. 2. Install the upper quarter trim. Page 11903 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Lift up on the front edge of the switch panel in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. If equipped, disconnect the electrical connectors from the driver door module (1). 4. If replacing only the driver door module, remove the module from the door trim panel. 5. Disconnect the remaining electrical connectors from the switch panel. 6. If replacing only the switch panel, retain the driver door module for transfer. 7. Remove the switch panel assembly from the vehicle Installation Procedure 1. Install the driver door module (1) to the door trim panel. 2. Connect the electrical connector to the driver door module. 3. If replacing the switch panel, connect the remaining electrical connectors. Important: When replacing the driver door module, the set up procedure must be performed. 4. If replacing the driver door module, program the driver door module. Refer to Service Programming System (SPS) (Remote Procedure) Service Programming System (SPS) (Pass-Thru Procedure) Service Programming System (SPS) (Off Board Remote Procedure) Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming and Personalization Description and Operation in Personalization. 5. Install the switch panel to the door trim panel, ensuring the front and rear retaining clips are fully seated. Switch Replacement - Door Lock and Side Window - Passenger Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 2009 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. NOTE: Do not perform this test for more than 2 minutes in order to prevent damaging the catalytic converter. 1. Remove the fuel pump relay (1) from the junction box (2). 2. Crank the engine. 3. Allow the engine to start and stall. 4. Crank the engine for an additional 3 seconds to ensure the relief of any remaining fuel pressure. 5. Disconnect the negative battery cable in order to avoid re-pressurizing the fuel system. 6. Install the fuel pump relay (1) to the junction box (2). 7. Tighten the fuel filler cap. Page 8907 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 8 1. Remove the key from the ignition. 2. Connect the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 3. Install the CPA (1) to the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 4. Connect the IP module yellow 4-way connector (1) located behind the IP support. 5. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. Page 7698 2. Connect the RF side impact module yellow 2-way connector (1) located under the passenger seat. 3. Install the CPA to the RF side impact module yellow 2-way connector (1) located under the passenger seat. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Page 403 Page 2358 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 1417 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the knock sensor harness connector (4). 3. Remove the knock sensor retaining bolt (3). 4. Remove the appropriate knock sensor (1 or 2). INSTALLATION PROCEDURE 1. Install the knock sensor (1 or 2) and the bolt (3). NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Tighten Tighten the sensor to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (4). 3. Lower the vehicle. Page 3844 Compression Check: Testing and Inspection Engine Compression Test Tools Required J 38722 Compression Tester A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. Important: The battery must be at or near full charge. 1. Remove the air duct from the throttle control module. 2. Remove the ignition control modules. 3. Disable the fuel system. 4. Remove the spark clues. 5. Measure the engine compression, using the following procedure: 5.1. Firmly install J 38722 to the spark plug hole. 5.2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 5.3. Check and record the readings on J 38722 at each stroke. 5.4. Disconnect J 38722. 5.5. Repeat the compression test for each cylinder. 6. Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. 7. The following are examples of the possible measurements: - When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. - When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. - When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. - When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 8. Install the air duct to the throttle body. 9. Install the spark plugs. 10. Enable the fuel system. 11. Install the ignition control modules. Page 617 Registered And Non-Registered Trademarks Part 3 Page 5479 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 7969 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Coil Spring Replacement Removal Procedure Notice: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Install the rear axle support. 3. Remove the shock absorber lower mounting bolts. Notice: Do not lower the rear axle so that the upper control arms contact the frame. Damage to the upper control arms will result. 4. Lower the rear axle. 5. Remove the rear coil springs. Installation Procedure Page 5017 Electronic Components Page 7373 Application Table Part 3 Location View Page 3876 Page 7566 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 10642 Page 11477 Disclaimer Page 198 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 9556 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 8428 Blower Motor Switch-Front Auxiliary Page 4375 Accelerator Pedal Position Sensor: Description and Operation The APP sensor is mounted on the accelerator pedal assembly. The APP is actually 2 individual APP sensors within 1 housing. There are 2 separate signal, low reference, and 5-volt reference circuits. APP sensor 1 voltage increases as the accelerator pedal is depressed. APP sensor 2 voltage decreases as the accelerator pedal is depressed. Page 12736 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer Removal Procedure 1. Remove the screw that retains the sealing strip to the door. 2. Lift upward on the rear edge of the sealing strip. 3. Remove the sealing strip from the pinch-weld flange. Installation Procedure 1. Install the sealing strip to the pinch-weld flange, starting at the forward edge of the door. 2. Ensure that the sealing strip is fully seated to the pinch-weld flange. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the sealing strip to the door. Tighten the screw to 1.2 N.m (10 lb in). Page 213 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 10345 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 13180 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the LF door trim panel. 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. Page 11839 Abbreviations And Meanings Part 24 Page 12334 3. Install the 3 bolts that retain the head restraint retractor assembly to the seat back frame. Tighten the head restraint retractor bolts to 10 N.m (88 lb in). 4. Install the seat back cover and pad. Head Restraint Guide Assembly Replacement - Rear No. 2 Head Restraint Guide Assembly Replacement - Rear No. 2 Removal Procedure 1. Remove the head restraint assembly. 2. Remove the seat back cover and pad to expose the seat back frame. 3. Gently pull the pad away from the seat back frame. It may be glued in places from its original assembly. 4. Remove the head rest restraint guides by squeezing the tabs on the bottom of the guide together and pulling the guide upward out of the seat. Installation Procedure 1. Install the head restraint guides by pushing them through the cover into the frame until the locking tabs snap into place. The guide with the locking tab (1) installs on the right hand side of the seat. 2. Install the seat back cover and pad on the seat back frame. 3. Install the head restraint assembly. Page 1048 and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Page 9644 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 436 Page 9082 10. Install the seat back bezel push pins. 11. Install the rear seat belt anchor to the seat belt buckle bracket with the nut. Tighten Tighten the rear seat belt anchor nut to 50 N.m (37 lb ft). 12. Install the rear seat back assembly. Page 9817 Abbreviations And Meanings Part 9 Page 13217 Fuel System - Fuel Spit-Back/Early Pump Nozzle Shut-Off Fuel Filler Neck: All Technical Service Bulletins Fuel System - Fuel Spit-Back/Early Pump Nozzle Shut-Off Bulletin No.: 04-06-04-003A Date: August 11, 2004 TECHNICAL Subject: Vehicle is Difficult to Fill with Fuel or Filling Station Pump Shuts Off Before Tank is Full or Fuel Spits Back/Out When Filling Tank (Replace Fuel Tank Filler Upper Pipe and Lower Hose) Models: 2003 Chevrolet TrailBlazer with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2003 GMC Envoy with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2003 Oldsmobile Bravada with 83 L (22 Gallon) Fuel Tank (RPO NNK) 2002-2003 Chevrolet TrailBlazer EXT 2002-2003 GMC Envoy XL 2004 Buick Rainier 2004 Chevrolet TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Envoy XUV 2004 Oldsmobile Bravada Built Prior to December 2003 Supercede: This bulletin is being revised to provide new part number for 2002-2003 vehicles. Please discard Corporate Bulletin Number 04-06-04-003 (Section 06 - Engine/Propulsion System). This bulletin provides information on two different conditions. Condition 1 Some customers may comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. Cause This condition may be caused by the variability (fuel flow rates, type of fuel fill nozzle, fuel properties) at the filling stations. There is a potential to develop an increase in back pressures internal to the fuel fill neck. This back pressure trips the fuel nozzle prior to filling the tank, or results in a hard to fill condition. Condition 2 Some customers may comment that when filling the fuel tank, a small amount of fuel may spit back/out. Cause This condition may be caused by the equalization of pressure between the fuel tank and the fuel fill neck that does not react quickly to the variance in the pressure when the fueling station fuel nozzle trips off. Correction Replace the fuel tank filler upper pipe assembly with P/N 88983256 or P/N 15131043, and lower hose assembly with P/N 15131046. The new upper pipe has been redesigned to provide smoother flow conditions within the section and the lower hose has been redesigned to include a checking feature. Use the procedure listed below. 1. Remove the fuel fill cap. 2. Remove the fuel fill pipe housing. Page 2678 14. Remove the left engine mount bracket bolts. 15. Remove the left engine mount bracket. 16. Remove the left frame engine mount bracket bolts, if required. 17. Remove the left frame engine mount bracket, if required. Installation Procedure 1. Install the left frame engine mount bracket, if removed. NOTICE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the left frame engine mount bracket bolts, if removed. Tighten the mount bracket bolts to 110 Nm (81 ft. lbs.). Page 10342 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 4679 Page 12469 14. Install the seat pan to the seat adjuster frame. 15. Install the 4 retaining nuts to the studs on the underside of the cushion. Tighten the nuts to 25 N.m (18 lb ft). 16. Install the 3 seat switch bezel screws. Seat Cushion Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada) Seat Cushion Replacement - Rear No. 1 (Trailblazer, Envoy, Bravada) Removal Procedure 1. Remove the rear seat bracket trim cover. 2. Remove the hydraulic jack from the jack stowage area, on the left side only. 3. Position the seat cushion assembly in order to gain access to the 2 rear seat mounting nuts. 4. Remove the 2 mounting nuts. 5. Remove the seat cushion assembly from the vehicle. Installation Procedure 1. Position the seat cushion assembly to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 2 nuts that retain the seat cushion assembly to the floor panel. Tighten the rear seat mounting nuts to 45 N.m (33 lb ft). 3. Install the hydraulic jack into the jack stowage area, on the left side only. 4. Adjust the seat cushion assembly to the latched position. 5. Install the rear mount trim cover. Seat Cushion Bracket Replacement - Rear No. 1 (TrailBlazer, Envoy, Bravada) Page 2815 Abbreviations And Meanings Part 13 Page 797 12. Disconnect the body wiring harness connector (1) from the junction block. 13. Disconnect the headliner harness connector (2) from the junction block. 14. Disconnect the console harness connector from the junction block. 15. Remove the block base retaining nuts from the floor studs. 16. Remove the block base from the floor panel. INSTALLATION PROCEDURE 1. Install the block base to the floor studs. 2. Install the block base retaining nuts to the floor studs. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the block base retaining nuts to 10 N.m (88 lb in). 3. Connect the console harness connector to the block base. 4. Connect the headliner harness connector (2) to the block base. 5. Connect the body wiring harness connector (1) to the block base. Page 12016 WA528F/76 - WA5322/33 Page 9657 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 7534 7. Remove the junction block bracket retaining bolts (1) and remove the junction block bracket from the vehicle. INSTALLATION PROCEDURE 1. Position the junction block bracket and install the bolts (1). Tighten Tighten the junction block bracket bolts to 6 N.m (53 lb in). 2. Align the wiring harnesses and install the fuse relay center. 3. Install the fuse relay center bolts (3). Tighten Tighten the relay center bolts to 6 N.m (53 lb in). Page 12255 Sunroof Module Page 2214 Fuse Block - Rear C1 Part 4 Page 2549 The trim tool cutter with the new trimmer pilot can be viewed from the bottom of the tool. Refer to the illustration above. 1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange. 2. Place metal shaving catch plug EN 45680-413 into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-413 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. 3. Place additional metal shaving catch plugs EN 45680-413 into all remaining cylinder bore sleeves. Page 14 Page 3577 Powertrain Control Module (PCM) C1 Part 3 Page 5501 Shift Solenoid: Diagrams 3-2 Shift Solenoid (SS) Valve Assembly Connector, Wiring Harness Side 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Slde Page 10546 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 3869 Page 6702 Abbreviations And Meanings Part 24 Page 10859 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Diagram Information and Instructions Oil Pressure Gauge: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 2564 20. Install a straight edge on the cylinder block perpendicular to the crankshaft center line. 21. Using a light, illuminate the backside of the straight edge. 22. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present of either side or both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed. 23. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly. 24. Proceed to the next cylinder bore sleeve to be trimmed repeat steps 10-23 if necessary. Page 7125 C800 Part 1 Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Removal Procedure 1. Open the hood. 2. Remove the rear hood seal from the inlet grille panel studs. 3. Remove the seal from the inlet grille panel. Installation Procedure 1. Position the seal to the inlet grille panel. 2. Install the rear hood seal to the inlet grille panel studs. 3. Close the hood. Page 2575 1. Connect the coolant heater cord retainers (1) to the battery cover. 2. If equipped with a 5.3L engine, connect the coolant heater cord to the coolant heater (1). 3. Install the coolant heater cord clip to the engine harness. 4. If equipped with a 4.2L engine, install the coolant heater cord to the coolant heater (2). 5. Install the coolant heater cord to the engine harness bracket (1). 6. Install the PCM. Page 8240 Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector to the mode actuator-auxiliary (1). 4. Install the right rear quarter trim panel. 5. Calibrate the HVAC module actuators, See: Testing and Inspection/Programming and Relearning Recirculation Actuator RECIRCULATION ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module assembly. 2. Remove the air inlet assembly. 3. Remove the screws from the air inlet assembly. 4. Remove the recirculation actuator screws. 5. Remove the recirculation actuator. INSTALLATION PROCEDURE 1. Install the recirculation actuator. 2. Install the recirculation actuator screws. NOTE: Refer toFastener Notice in Service Precautions. Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Install the air inlet assembly. Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor (VSS) Page 12112 Page 6182 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Page 5650 1. Install a new retaining ring (E-clip) into the quick connect fining using the following procedure: 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fining. 3. Rotate the retaining ring around the fining until the retaining ring is positioned with all three ears through the three slots on the fining. 4. Do not install the new retaining ring onto the fining by pushing the retaining ring. Page 549 Page 1724 Equivalents - Decimal And Metric Part 1 Equivalents - Decimal And Metric Part 2 Page 10253 Amplifier: Diagrams Audio Amplifier C3 (With RPO Code UQA) Audio Amplifier C3 (With RPO Code UQA) Part 1 Audio Amplifier C3 (With RPO Code UQA) Part 2 Page 9604 Disclaimer Page 2329 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Page 13734 1. Install the horn switch (2) to the steering wheel (3). Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the horn contact plate (2) captured screws (1, 4) to the steering wheel (3). Tighten the screws to 5.5 Nm (50 inch lbs.). 3. Install the horn plunger to the steering column. 4. Install the inflator module. 5. Enable the SIR system. Page 9774 Page 12343 3. Install the screw that retains the seat control module to the seat pan. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat module screw to 3 N.m (26 lb in). 4. Install the seat pan to the seat assembly. 5. Install the nuts which retain the seat pan to the seat assembly. Tighten Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 6. Install the 3 seat switch bezel screws. Page 8388 Abbreviations And Meanings Part 8 Page 4288 Abbreviations And Meanings Part 22 Page 4818 Ignition Coil 2 Page 4529 Steps 16-19 Page 8242 Air Door Actuator / Motor: Service and Repair Manual Control Auxiliary AIR TEMPERATURE ACTUATOR REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Disconnect the electrical connector from the air temperature actuator. 3. Remove the retaining screws from the air temperature actuator. 4. Remove the air temperature actuator (1) from the rear HVAC module. INSTALLATION PROCEDURE 1. Install the air temperature actuator (2) to the rear HVAC module. 2. Install the screws to the actuator. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector to the air temperature actuator. 4. Recalibrate the air temperature actuator, See: Testing and Inspection/Programming and Relearning Page 4067 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols ELECTRICAL SYMBOLS Page 8951 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 2 and SIR Disabling and Enabling Zone 6. CAUTION: Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the front door trim panel. 3. Peel the rear half of the water deflector away from the door in order to access the side impact sensor. 4. Remove the screws that retain the side impact sensor (2) to the door. 5. Disconnect the impact sensor electrical connector (1) from the side impact sensor. 6. Remove the side impact sensor from the door. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Position the side impact sensor (2) horizontally to the door. 3. Connect the electrical connector (1) to the side impact sensor (2). 4. Install the screws which retain the side impact sensor to the door. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Page 12322 5. Install the seat assembly. Head Restraint Cover Replacement - Front Seat HEAD RESTRAINT COVER REPLACEMENT - FRONT SEAT REMOVAL PROCEDURE 1. Remove the front seat head restraint. 2. Release the J-strips on the bottom of the head restraint cover. 3. Remove the cover from the head restraint. INSTALLATION PROCEDURE Page 12792 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 11724 1. Remove the cargo shade/cover. 2. Remove the left body side upper trim panel. 3. Remove the liftgate sill plate. 4. Remove the left rear door sill panel. 5. Remove the lower seat belt anchor bolt. 6. Release the clips that retain the trim panel to the body. 7. Remove the trim panel from the vehicle. Installation Procedure 1. Position the trim panel to the vehicle. 2. Position the seat belt over the top of the trim panel, ensuring that the buckle is not behind the trim panel. 3. Index the locating tabs on the trim panel to the holes in the body. 4. Seat the clips the retain the trim panel to the body. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the seat belt lower anchor. Tighten the anchor bolt to 70. N.m (52 lb ft). 6. Install the left rear door sill panel. 7. Install the liftgate sill plate. 8. Install the left body side upper trim panel. Trim Panel Replacement - Rear Quarter - Right (TrailBlazer EXT, Envoy XL) Trim Panel Replacement - Rear Quarter - Right (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the cargo shelf. 2. Tumble the third row seats to the cargo position. 3. Remove the right body side window rear garnish molding. 4. Remove the right body side window forward garnish molding.. 5. Remove the liftgate sill plate. Page 8375 - M8 X 1.25 - M10 X 1.5 - M12 X 1.75 - M14 X 2.00 - M16 X 2.00 PREVAILING TORQUE FASTENERS Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. ALL METAL PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. NYLON INTERFACE PREVAILING TORQUE FASTENERS These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. ADHESIVE COATED FASTENERS These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener. A prevailing torque fastener may be reused ONLY if: The fastener and the fastener counterpart are clean and not damaged - There is no rust on the fastener - The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Page 3534 10. With an upward motion, remove the BCM (1) from the rear electrical center. INSTALLATION PROCEDURE 1. Index the slots on the BCM (1) to the rear electrical center. 2. Using a downward motion, install the BCM to the rear electrical center. Page 7204 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 425 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 7966 Tighten the clamps to 2.5 N.m (22 lb in). 17. Lower the vehicle. 18. Install the fuel fill pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the fuel fill pipe housing. 20. Install the fuel fill cap. Parts Information Parts are expected to be available from GMSPO on August 13, 2004. Warranty Information For vehicles repaired under warranty use the table. Disclaimer Page 13030 Registered And Non-Registered Trademarks Part 5 Page 8898 6. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 7. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Zone 6 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the RF door trim panel. Service and Repair Coolant Drain Plug: Service and Repair Drain Cock Replacement Removal Procedure 1. Drain cooling system. 2. Use a 1/4 inch drive in order to open and remove the drain cock. 3. Remove the drain cock. Installation Procedure 1. Install the drain cock. Notice: Refer to Fastener Notice in Service Precautions. 2. Using a 1/4 inch drive tighten the drain cock. ^ Tighten the drain cock to 2.0 Nm (18 inch lbs.). 3. Refill cooling system. Page 13173 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE Fuel Sender Assembly 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector. 3. Remove the retaining clip from the fuel level sensor connector. 4. Disconnect the electrical connector from under the fuel sender cover. 5. Remove the sensor retaining clip. 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE Fuel Sender Assembly 1. Install the fuel level sensor (3). 2. Install the sensor retaining clip. 3. Connect the electrical connector to the fuel level sensor. 4. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Page 3792 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Page 10379 Registered And Non-Registered Trademarks Part 6 Page 9391 Abbreviations And Meanings Part 25 Page 7470 C201 Part 3 Page 12868 Recall - Windshield Wiper Defect Technical Service Bulletin # 04005 Date: 040701 Recall - Windshield Wiper Defect File In Section: Product Recalls Bulletin No.: 04005 Date: July, 2004 PRODUCT SAFETY RECALL SUBJECT: WINDSHIELD WIPER OPERATION MODELS: 2002-2003 CHEVROLET TRAILBLAZER, TRAILBLAZER EXT 2002-2003 GMC ENVOY, ENVOY XL 2002-2003 OLDSMOBILE BRAVADA CONDITION General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002 and 2003 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and Oldsmobile Bravada vehicles. Under certain conditions, water may seep into the windshield wiper module. If this were to happen, it could result in windshield wipers that will not turn on, cease operation while driving, fail to turn off, turn on by themselves, and/or continuous windshield washer pump operation. Improper operation of the windshield wiper system in a severe weather situation could reduce the driver's visibility, resulting in a possible vehicle crash without prior warning. CORRECTION Dealers are to inspect and seal the windshield wiper motor. In some cases, the windshield wiper module may require replacement. VEHICLES INVOLVED Involved are certain 2002 and 2003 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and Oldsmobile Bravada vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Page 12356 Memory Seat Module - Driver C3 Part 1 Memory Seat Module - Driver C3 Part 2 Page 681 Power Trunk / Liftgate Control Module: Service and Repair LIFT GATE CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the liftgate window garnish molding. 2. Remove the liftgate trim panel. 3. Disconnect the electrical connectors (3) from the module as necessary. 4. Remove the bolts that retain the module to the liftgate. 5. Remove the module from the liftgate. INSTALLATION PROCEDURE 1. Install the module to the liftgate. 2. Install the bolts that retain the module to the liftgate. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Connect the electrical connectors (3) as necessary. 4. Install the liftgate trim panel. 5. Install the liftgate window garnish molding. 6. Reprogram the liftgate control module. Refer to Lift Gate Control Module Programming. Page 2023 Heater Hose: Service and Repair Heater Hose - Outlet With RPO Code LL8 HEATER HOSE REPLACEMENT - OUTLET (LL8) See: Application and ID/RPO Codes TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 2. Remove the transmission. 3. Remove the generator. 4. Using the J 43181 disconnect the outlet hose from the heater core outlet tube (1). 4.1. Install the J 43181 to the outlet heater core hose. 4.2. Close the tool around the outlet heater core hose. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the heater outlet hose (3) from the heater core (1). 6. Position the outlet heater hose clamp (6) at the water pump using J 38185. Page 11470 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 06-06-04-048B Date: 070112 Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Page 9335 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 8714 fan noise can be expected with the updated PCM software calibrations. The last area of customer concern is the operation of the HVAC system blower motor. For vehicles equipped with automatic control HVAC systems (RPO CJ2), the blower motor fan speed will be limited to 80% of maximum when the HVAC system is operating in the automatic mode. To obtain maximum blower motor speed, instruct the customer to manually adjust the blower motor speed to the highest setting. Parts Information Warranty Information (excluding Saab U.S. Models) Disclaimer Page 8054 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: All Technical Service Bulletins Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 12979 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 2813 Abbreviations And Meanings Part 11 Page 2898 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 669 Memory Seat Module - Passenger C4 Part 1 Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 2473 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12 volt positive, negative ground electrical system. Do not try to jump start a vehicle if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed. Leave the hazard flashers ON. 2.5. Turn OFF the ignition switch. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: 8.1. Turn the ignition OFF. 8.2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. 8.3. Attempt to start the engine of the vehicle with the discharged battery. 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump Page 12500 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 10287 Speaker: Service and Repair Speaker Replacement - Front Upper SPEAKER REPLACEMENT - FRONT UPPER REMOVAL PROCEDURE 1. Remove the trim pad. 2. Remove the 3 screws that retain the speaker to the instrument panel (IP) substrate. IMPORTANT: Ensure that the speaker electrical connector does not fall into the speaker opening. 3. Disconnect the speaker electrical connector. 4. Remove the speaker from the IP. INSTALLATION PROCEDURE Page 13685 1. Remove the 2 screws that retain the insulator panel to the instrument panel (I/P). 2. Release the insulator panel retaining clip from the I/P substrate. 3. Lower the insulator panel. 4. Remove the flasher retaining bracket from the insulator panel. 5. Disconnect the flasher from the electrical connector. 6. Remove the flasher from the vehicle. 7. Position the new flasher to the insulator panel. 8. Connect the electrical connector to the flasher. 9. Install the flasher retaining bracket to the insulator panel. 10. Install the insulator panel tabs to the cowl slots. 11. Raise the insulator panel to the I/P. 12. Install the insulator panel retaining clip to the I/P substrate. 13. Install the 2 screws that retain the insulator panel to the I/P. Tighten Tighten the screws to 2.5 N.m (22 lb in). Page 8649 2. Install the evaporator tube. Notice: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings 3. Connect the evaporator tube to the evaporator (5). Tighten Tighten the nut to 28 N.m (21 lb ft). 4. Connect the auxiliary evaporator tube to the auxiliary piping. Tighten Tighten the nut to 28 N.m (21 lb ft). 5. Connect the evaporator tube to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). 6. Install the coolant recovery tank. 7. Install the washer solvent container. 8. Install the nuts (1, 2) retaining the evaporator tube to the fender. Tighten Tighten the nuts to 28 N.m (21 lb ft). 9. Evacuate and recharge the A/C system. 10. Leak test the fittings of the components using the J 39400. Page 12158 Abbreviations And Meanings Part 3 Page 13150 Abbreviations And Meanings Part 22 Page 3616 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn the engine OFF. 2. Disconnect the negative battery terminal. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 3. Drain coolant below the level of the ECT sensor. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. 4. Disconnect the ECT sensor electrical connector (1). 5. Remove the drive belt and the generator. 6. Carefully remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the Engine Controls - A/T Slipping/No SES Lamp/No DTC Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - A/T Slipping/No SES Lamp/No DTC Set Transmission Slipping or Torque Converter Clutch (TCC) Inoperative with No SES Light Displayed and No DTC P1870 (Reprogram PCM and Diagnose Vehicle Using P1870 Diagnostic Table) # 03-07-30-001A - (Mar 14, 2005) Models: 2003 Chevrolet TrailBlazer, TrailBlazer EXT 2003 GMC Envoy, Envoy XL 2003 Oldsmobile Bravada Built Within the Build Dates shown. This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 03-07-30-001 (Section 07 - Transmission/Transaxle) Condition Some customers may comment that the transmission appears to be slipping or that the vehicle has no TCC apply. This condition should not be confused with a noisy cooling fan. Refer to Corporate Bulletin Number 99-07-30-016B for additional information on fan noise. Investigation of the condition may show no fail records, freeze frame or DTC associated with the condition. This condition might normally have set diagnostic trouble code (DTC) P1870. Important: Please note that this is a MISSING DTC P1870. This condition will NOT cause a DTC P1870 to be set. Cause The operating software may not allow DTC P1870 (Transmission Component Slipping) diagnostic test to run. This condition is not an impairment to the operation of the vehicle or the transmission. Correction The vehicle should be checked to verify DTC P1870 is supported in the operating software. 1. Install the scan tool. 2. Navigate to "Specific DTC." 3. Enter P1870. 4. If the DTC is supported, the scan tool will report the status of DTC P1870. Continue with normal service diagnostics. 5. If the DTC is not supported, the scan tool will report "Invalid DTC." The vehicle PCM must be reprogrammed using TIS version 9, broadcast in August 2002, or newer, and then diagnosed for no TCC operation using the SI information for P1870. Warranty Information Page 13144 Abbreviations And Meanings Part 16 Page 2253 Location View OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 2287 6. Connect the mobile telephone harness connector (1) to the junction block. 7. Connect the instrument panel harness connector (1) to the block base. 8. Install the junction block to the block base. Ensure that the retaining tabs are fully seated. Page 2094 1. Install the rear axle drain plug. Tighten the rear axle drain plug to 48 Nm (35 ft. lbs.). 2. Fill the rear axle with axle lubricant. Use the proper fluid. 3. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 4. Lower the vehicle. Page 4356 Powertrain Control Module (PCM) C1 Part 5 Page 4276 Abbreviations And Meanings Part 10 Page 10360 Abbreviations And Meanings Part 13 Page 6290 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Locations Page 2543 2. Install the cylinder bore sleeve puller EN 45680-402 (1), which is part of EN 45680-400, through the cylinder bore. Note: Ensure that the shoe is flat against the bottom of the cylinder bore sleeve or damage to the cylinder bore sleeve puller EN 45680-402 will occur. 3. Align the shoe (1) of the cylinder bore sleeve puller EN 45680-402 to the bottom of the cylinder bore sleeve (117). 4. Hold the threaded shaft of the cylinder bore sleeve puller EN 45680-402 upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve. 5. Install the fixture EN 456850-401(4) onto the threaded shaft of the cylinder bore sleeve puller EN 456850-402 and the engine block. 6. Install the bearing (3) and the nut (1). 7. Tighten the nut (1) to the bearing (3). Important: Use four old cylinder head bolts for the attaching bolts. 8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten Tighten the bolts to 15 N.m (11 lb ft). 9. Rotate the nut clockwise in order to remove the cylinder bore sleeve. Body - Liftgate Glass Binds/Won't Open Fully Center Mounted Brake Lamp: All Technical Service Bulletins Body - Liftgate Glass Binds/Won't Open Fully Bulletin No.: 04-08-66-017 Date: November 09, 2004 TECHNICAL Subject: Liftgate or Liftgate Glass Binds, Does Not Open Completely, CHMSL Hits Roof (Remove Material from CHMSL Applique) Models: 2002-2005 Chevrolet TrailBlazer EXT 2002-2005 GMC Envoy XL Condition Some customers may comment that the liftgate or liftgate glass binds when opening or does not open all the way. Cause This condition is caused by the Center High Mounted Stop Lamp (CHMSL) applique hitting the roof of the vehicle. Correction Verify that the CHMSL applique is not loose or broken off one or more of its mounting points. If the applique is broken, it will be necessary to order a replacement part. Important: ^ It should not be necessary to replace the liftgate glass. ^ All measurements and alterations should take place prior to paint finish. ^ It is necessary to install any replacement parts in order to measure to determine if further modification is required. To achieve the proper clearance, modification to the applique is required using the following procedure: 1. Measure (with applique installed) the area of interference in order to determine the material to be removed. ^ The top surface (height) of the applique should line up approximately 1 mm (0.039 in) below the top surface of the roof. ^ A gap of 6-8 mm (0.236-0.315 in) should exist between the roof and the applique to allow for adequate clearance while opening the liftgate. Page 7036 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 1520 32. Install the new hose (1), # 1005 (L6 engine) or# 1006 (V8 engine) onto the coolant bypass valve at the location the above hose was removed. The other end of this hose will be installed on the auxiliary heater pump outlet port. Page 7370 Fuse Block: Application and ID Fuse Block - Rear (Short Wheelbase) Location View Page 3182 For vehicles repaired under warranty, use the table. Disclaimer Page 3744 3. Remove the J 34730-1A from the pressure gage fitting. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the fuel pressure service connection cap. 6. Inspect for leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 7. Install the fuel tank shield if removed. Page 1036 Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for inspecting the windshield wiper module, installing a breathable seal to the vent on the wiper motor cover if applicable, or if necessary, installing a new windshield wiper module. INSPECTION PROCEDURE 1. Using a flashlight, look down through the air inlet screen (1) at the location shown. ^ If the color of the can (2) on the wiper motor is SILVER, no repairs are required on the vehicle. ^ If the color of the can (2) on the wiper motor is BLACK, proceed to the section below titled, REPAIR PROCEDURE. REPAIR PROCEDURE 1. Verify that all of the functions of the wiper system (low, high, delay, etc.) operate properly. 2. Turn the key to the OFF position. 3. Open the hood. Page 12730 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Opening Weatherstrip Replacement - Front Door Opening Removal Procedure 1. Remove the front door sill plate. 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. Page 2069 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water (if the water in your area is of poor quality, it is recommended you use distilled or de-ionized water) and DEX-COOL coolant will: - Give freezing protection down to -34°F (-37°C). - Give boiling protection up to 265°F (129°C). - Protect against rust and corrosion. - Help keep the proper engine temperature. - Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Page 9918 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Locations Engine, Right Front Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Only if necessary remove the fuel tank shield. IMPORTANT: Due to an access hole in the fuel tank shield, removal of the shield should not be necessary to access the fuel pressure service connection. 3. Remove the fuel pressure service connection cap, located near the fuel filter. 4. Install the J 34730-1A fuel pressure gage to the fuel pressure service connection, located near the fuel filter. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Turn ON the ignition. 6. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 7. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 8. Command the fuel pump ON with a scan tool. 9. Close the bleed valve on the fuel pressure gage. 10. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. 2. Place a shop towel under the fuel pressure gage adaptor fitting to catch any remaining fuel spillage. Page 7503 C700 Part 2 Page 1703 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 5459 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Recall - Rear Side Door Latch Corrosion Technical Service Bulletin # 05077 Date: 060216 Recall - Rear Side Door Latch Corrosion Bulletin No.: 05077 Date: February 16, 2006 SAFETY Subject: 05077- REAR SIDE DOOR CLOSURE Models: 2002-2003 CHEVROLET TRAILBLAZER EXT 2002-2003 GMC ENVOY XL LOCATED IN CORROSION AREAS Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2002-2003 Chevrolet TrailBlazer EXT and GMC Envoy XL vehicles that have ever been registered in corrosion areas. The rear side doors on these vehicles may not latch or may not unlatch properly due to corrosion caused by road splash, such as water and road salt. Depending on the location of the corrosion in the latch, the door may either be difficult to open from the inside or outside, or may bounce back when the door is swung shut from the outside. The driver information center may or may not indicate that the door is ajar. If the door is not latched properly and it goes unnoticed, it may open while the vehicle is in motion. If the occupant is unbelted, they may fall out of the vehicle and personal injury could occur. Correction Dealers are to install a seal to prevent water intrusion into the latch. The latch is also to be inspected and replaced, if necessary. Vehicles Involved Page 11396 5. Close the liftgate. 6. Open the liftgate window. 7. Install the push-pin retainer. 8. Close the liftgate window. Page 7096 C301 Part 2 Page 10902 Body Control Module (BCM) C1 Part 3 Page 10533 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 5211 11. Remove the servo cover and the O-ring seal. If the cover is hung up on the seal, use a pick (2) to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 12. Remove the 2-4 servo from the transmission. 13. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects. ^ Cracks ^ Scoring ^ Burrs and nicks Installation Procedure 1. Install new seals on the servo pistons and the servo cover. 2. Install the 2-4 servo assembly into the transmission. 3. Install the J29714-A. Page 12279 10. Remove the inboard retainer screw. 11. Remove the inboard retainer (1) from the headliner. 12. If the vehicle is equipped with lighted sunshades, perform the following steps. 12.1. Reach above the headliner to access the electrical connector (1). 12.2. Remove the electrical connectors from the headliner substrate. 12.3. Disconnect the sunshade electrical connector from the headliner harness. 13. Remove the sunshade from the vehicle. Installation Procedure 1. If the vehicle is equipped with lighted sunshades, perform steps 2 through 8. 2. Lower the headliner in order to gain access to the wire harness. 3. Position the sunshade to the headliner. 4. Connect the sunshade electrical connector to the headliner harness. Page 1166 Page 1114 Seat Lumbar Motors And Position Sensors Assembly - Driver Part 2 Page 3347 6. Install the outlet radiator hose (1) to the radiator. 7. Reposition the outlet radiator hose clamp (1) using J 38185. 8. Connect the transmission cooler lines to the radiator. 9. Install the lower radiator support shield, if equipped. 10. Lower the vehicle. 11. Install the coolant recovery hose to the radiator. 12. Install the radiator support diagonal brace. 13. Fill the cooling system. Page 2935 Abbreviations And Meanings Part 7 Page 3821 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12 Locations Memory/Heated Seat Switches A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 13108 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 13143 Abbreviations And Meanings Part 15 Page 3839 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Turn OFF the ignition switch. 2. Remove the ignition coils. Refer to Ignition Coil Replacement. Notice: Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads. Notice: Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination. 3. Remove the spark plugs from the engine. Installation Procedure Notice: Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine. Notice: Check the gap of all new and reconditioned spark plugs before installation. The pre-set gaps may have changed during handling. Use a round feeler gauge to ensure an accurate check. Installing the spark plugs with the wrong gap can cause poor engine performance and may even damage the engine. 1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. Refer to Ignition System Specifications, See: Specifications Correct as necessary. Notice: Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Page 4122 Abbreviations And Meanings Part 8 Page 3189 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Page 8043 Tires: Diagrams Tire Rotation In order to equalize wear, rotate the tires at the specified intervals. In addition to scheduled rotation, rotate the tire and wheel assembly whenever you notice uneven tire wear. Radial tires tend to wear faster in the shoulder area, particularly in front positions, due to design. Radial tires in non-drive locations may develop an irregular wear pattern that can generate tire noise. This especially makes regular tire rotation necessary. - For vehicles with single rear wheels (four tires), rotate the tires as shown. - For vehicles with single rear wheels (five tires), rotate the tires as shown. - For vehicles with dual rear wheels (same tire sizes and load ranges), rotate the tires as shown. Page 5717 Page 10537 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake Pressure Modulator Bleeder Valves 80 inch lbs. EHCU to Bracket 7 ft. lbs. EHCU Bracket Mounting Bolts 18 ft. lbs. Page 13218 Page 13687 Page 13271 Abbreviations And Meanings Part 9 Page 4362 Powertrain Control Module (PCM) C2 Part 6 Page 12333 2. Remove the 3 bolts that retain the head restraint retractor assembly to the seat back frame. 3. Partially remove the head restraint retractor assembly from the frame. 4. Remove the release cable by sliding the cable retainer over to the large access hole and removing the cable from the head restraint retractor assembly. 5. Remove the retractor assembly from the seat back frame. Installation Procedure 1. Position the head restraint retractor assembly to the seat back. 2. Install the release cable through the head restraint retractor assembly access hole and sliding the cable retainer into position. Notice: Refer to Fastener Notice in Service Precautions. Page 2384 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 9624 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 3518 Body Control Module (BCM) C1 Part 2 Service and Repair Power Steering Line/Hose: Service and Repair Power Steering Hose Assembly Replacement Tools Required ^ J44586 Power Steering Gear Oil Seal Remover/Installer Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Raise the vehicle and support with suitable safety stands. 2. Install a drain pan under the vehicle. 3. Remove the power steering hose assembly to the power steering gear retaining bolt. 4. Disconnect the power steering hose assembly from the power steering gear. 5. Remove the power steering return hose and power steering cooler hose from the power steering cooler. 6. Lower the vehicle. 7. Disconnect the fuse block wiring harnesses from the wiring loops. 8. Remove the fuse block. 9. Remove the battery tray. Page 9887 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lift up on the front edge of the door lock and side window switch (1) in order to release the front retaining clip. 2. Lift up on the rear edge of the switch panel in order to release the 2 rear retaining clips. 3. Remove the electrical connector (2) from the memory seat switch. 4. Remove the memory seat switch from the lock and door lock and side window switch (1). INSTALLATION PROCEDURE Page 7459 C101 Part 3 Locations Cabin Temperature Sensor / Switch: Locations Instrument Panel Carrier - Right Side Instrument Panel Carrier - Center Section Page 7730 Steering Gear Disassembled View Page 2229 Fuse Block - Underhood C1 Part 2 Page 6710 Registered And Non-Registered Trademarks Part 6 Page 573 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 1657 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 8628 Heater Core: Service and Repair Heater Core Replacement - Auxiliary HEATER CORE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the HVAC module-auxiliary. See: Housing Assembly HVAC/Service and Repair 2. Remove the screws from heater core cover-auxiliary (3) from the HVAC module-auxiliary. 3. Remove the heater core cover-auxiliary (3). 4. Remove the HVAC module pass thru seal-auxiliary. 5. Remove the heater core-auxiliary (2) from the HVAC module-auxiliary. INSTALLATION PROCEDURE 1. Install the heater core-auxiliary (2) to the HVAC module-auxiliary. 2. Install the HVAC module pass thru seal-auxiliary. 3. Install the heater core access cover-auxiliary (3) to the HVAC module-auxiliary. 4. Install the screws to the heater core access cover-auxiliary (3). Tighten the screws to 2 N.m (18 lb in). NOTE: Refer to Fastener Notice in Service Precautions. OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 1135 2. Install the seat switch to the seat bezel assembly. Verify that the retaining tabs are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. The scan tool instructs you to perform the following items: - Accelerate to wide open throttle (WOT). - Release the throttle when fuel cut-off occurs. - Observe the fuel cut-off for the engine that you are performing the learn procedure on. - The engine should not accelerate beyond calibrated RPM value. - Release the throttle immediately if value is exceeded. - Block the drive wheels. - Set the parking brake. - DO NOT apply the brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn the A/C OFF. - The vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. With the scan tool, enable the crankshaft position system variation learn procedure. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release the throttle when the fuel cut-off occurs. 8. The scan tool displays Learn Status-Learned this ignition: - If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. - If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. - If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The crankshaft position system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P1336 sets: Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - Crankshaft position sensor replacement - Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Diagrams Sunroof Motor Page 12976 REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 7846 10. Install the outer tie rod to the steering knuckle. 11. Install the outer tie rod retaining nut. Tighten the nuts to 45 Nm (33 ft. lbs.). 12. Install the tire and wheel. 13. Lower the vehicle. 14. Check ten front wheel alignment. Page 3586 Engine Control Module: Diagrams Powertrain Control Module (PCM) C3 Powertrain Control Module (PCM) C3 Part 1 Page 7496 C316 Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 13296 Oil Pressure Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 12977 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS Page 12929 Abbreviations And Meanings Part 18 Ambient Air Temperature Sensor Replacement Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the front grille. 2. Remove the sensor (1) from the panel assembly (2). 3. Disconnect the electrical connector from the sensor (1). INSTALLATION PROCEDURE 1. Position the sensor to the panel assembly. 2. Connect the electrical connector to the sensor (1). Page 7473 C203 Page 2926 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 13261 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 2647 Disclaimer Page 781 Page 13727 Headlamp Switch C1 Part 2 OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 9847 Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures - Symptoms - Garage Door Opener SYMPTOMS - GARAGE DOOR OPENER IMPORTANT: Review the system description and operation in order to familiarize yourself with the system functions. Refer to Garage Door Opener Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the garage door opener. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to Garage Door Opener Inoperative in order to diagnose the symptom. Steps 1-3 Page 12069 WA8554/40 - WA8554/40 Page 7762 The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 2. Turn the steering wheel so that the front wheels are pointing straight ahead. 3. Turn the ignition switch to the lock position and remove the key. 4. Lock the steering column through the access hole in the lower steering column trim cover using the J 42640. 5. Raise and support the vehicle. 6. Disconnect the upper intermediate shaft boot from the lower intermediate shaft boot to gain access to the upper intermediate shaft to lower intermediate pinch bolt. 7. Remove the lower intermediate shaft to upper intermediate shaft pinch bolt. 8. Disconnect the lower intermediate shaft from the upper intermediate shaft. 9. Lower the vehicle 10. Attempt to duplicate the customer's concern again. ^ If the noise is still present with the intermediate shaft disconnected, DO NOT replace the intermediate shaft. ^ If the noise is not present, continue with the next step. 11. Raise and support the vehicle. Page 9436 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 4223 Page 13083 Page 9213 Steps 8-12 Page 12060 WA711J/58 - WA722J/25 Page 7786 Tighten the lower intermediate shaft to the upper intermediate shaft pinch bolt to 50 Nm (37 ft. lbs.). Important: The upper intermediate shaft boot must completely cover the white insert of the lower intermediate shaft boot to ensure proper sealing. 8. Connect the upper intermediate shaft boot to the lower intermediate shaft boot. 9. Unlock the steering column by removing J42640 from the steering column lower trim cover access hole. Page 8876 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P upper trim pad. 2. Remove the sun load sensor from the I/P upper trim pad by turning counter clockwise. 3. Disconnect the electrical connector from the sun load sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sun load sensor. 2. Install the sun load sensor to the I/P upper trim pad by turning clockwise. 3. Install the I/P upper trim pad. Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Interior - Elimination Of Unwanted Odors Carpet: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 5263 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8216 Mode Actuator-Auxiliary (Body Type VIN 3) Page 12649 Memory Seat Switch, Driver Door Module (DDM) - C4 Diagrams Windshield Wiper/Washer Switch (Turn Signal/Multifunction Switch C3) Page 4060 Fuel Tank Pressure (FTP) Sensor Page 3800 Seal removed without any damage to the air inlet grille panel plastic staked studs. Refer to the above illustration (1). Remove any dirt or debris from the sealing surface of the air inlet grille panel Install AIP seal, P/N 25788476. The revised seal has a foam weatherstrip attached to the bottom. Refer to the above illustration (1). The foam weatherstrip faces the air inlet grille panel. Carefully stretch the revised AIP rubber seal over the plastic staked studs of the air inlet grille panel without damaging them. Parts Information Warranty Information (excluding Saab U.S. Models) Page 8344 Page 223 Page 2431 Installation Procedure 1. Install the splash shield to the steering knuckle. Align the splash shield to the steering knuckle threaded holes. 2. Install the wheel hub and bearing to the steering knuckle. Align the threaded holes. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel hub and bearing to the steering knuckle mounting bolts. Tighten the wheel hub and bearing mounting bolts to 105 Nm (77 ft. lbs.). 4. Install the ABS sensor to the wheel hub and bearing. 5. Install the ABS sensor mounting bolt to the wheel hub and bearing. Tighten the ABS sensor to the wheel hub and bearing mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the brake rotor. 7. Install the tire and wheel. Page 1421 Manifold Absolute Pressure (MAP) Sensor Page 6648 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 8818 Front Auxiliary Blower Motor Switch (w/Automatic HVAC System / Body Type VIN 6) Page 2654 component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Page 13138 Abbreviations And Meanings Part 10 Page 4290 Abbreviations And Meanings Part 24 Page 579 Conversion - English/Metric Part 1 Page 12853 Registered And Non-Registered Trademarks Part 4 Page 4323 6. Install the rear electrical center cover. 7. If replacing the body wiring harness extension on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left hand second seat to a passenger position. 8. If replacing the body wiring harness extension on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 9. Connect the negative battery cable. Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Page 9207 Steps 1-4 Locations Stop Lamp Switch Page 10048 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 11862 Door Control Module Diagram 2 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 8804 Air Temperature Sensor Assembly-Inside Door Handle Replacement - Rear Outside (TrailBlazer EXT, Envoy XL) Rear Door Exterior Handle: Service and Repair Door Handle Replacement - Rear Outside (TrailBlazer EXT, Envoy XL) Door Handle Replacement - Rear Outside (Trailblazer EXT, Envoy XL) Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Release the clip (1) retaining the lock rod (2) to the outside door handle. 4. Remove the lock rod (2) from the outside door handle. 5. Remove the nuts retaining the outside door handle to the door. 6. Remove the outside door handle from the door. Installation Procedure 1. Install the outside door handle to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the nuts retaining the outside door handle to the door. Tighten the nuts to 10 N.m (89 lb in). 3. Install the lock rod (2) to the outside door handle. 4. Install the clip (1) retaining the lock rod (2) to the outside door handle. 5. Install the water deflector. 6. Install the door trim panel. Page 7446 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 9064 Seat Belt Switch-LF Page 4784 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor The camshaft position (CMP) sensor is triggered by a notched reluctor wheel built into the exhaust camshaft sprocket. The CMP sensor provides six signal pulses every camshaft revolution. Each notch, or feature of the reluctor wheel is of a different size for individual cylinder identification. This means the CMP and CKP signals are pulse width encoded to enable the PCM to constantly monitor their relationship. This relationship is used to determine camshaft actuator position and control its phasing at the correct value. The PCM also uses this signal to identify the compression stroke of each cylinder, and for sequential fuel injection. The CMP sensor is connected to the PCM by a 12-volt, low reference, and signal circuit. Page 10425 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 7607 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Uneven brake adjustment ^ Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Page 6911 Abbreviations And Meanings Part 26 Page 13774 Parts are currently available from GMSPO. Disclaimer Diagrams Driver Door Lock Cylinder Switch - LF Page 3946 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 6495 Parking Brake Cable: Service and Repair Enabling the Park Brake Cable Automatic Adjuster Enabling the Park Brake Cable Automatic Adjuster 1. Lower the park brake lever. 2. Raise the park brake lever. 3. Lift the park brake lever boot to gain access to the multiplier lever at the front of the park brake lever assembly. 4. Pivot the multiplier lever up and down 3 times. 5. Cycle the park brake lever up and down three times for auto adjustment. 6. Lower the park brake lever boot. Page 9389 Abbreviations And Meanings Part 23 Page 10414 Page 447 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 12784 Page 2899 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Body - Door(s) Are Difficult To Close Rear Door Striker: All Technical Service Bulletins Body - Door(s) Are Difficult To Close Bulletin No.: 03-08-64-006C Date: March 29, 2007 TECHNICAL Subject: Doors Hard to Close (Adjust Striker) Models: 2004-2007 Buick Rainier 2002-2006 Chevrolet TrailBlazer EXT 2002-2007 Chevrolet TrailBlazer 2002-2006 GMC Envoy XL 2002-2007 GMC Envoy 2004-2005 GMC Envoy XUV 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the warranty information. Please discard Corporate Bulletin Number 03-08-64-006B (Section 08 - Body and Accessories). Condition Some customers may comment that one or more of the doors may be hard to close. Cause The door striker may be out of adjustment. Correction Open the door. Remove the lock striker from the door opening. Close the door with the lock striker removed. Verify proper fit to the door opening and weatherstrips. Adjust the door frame as necessary. Install the lock striker to the door opening. Page 3992 Crankshaft Position Sensor: Description and Operation The crankshaft position (CKP) sensor is a permanent magnet generator, known as a variable reluctance sensor. The magnetic field of the sensor is altered by a crankshaft mounted reluctor wheel that has seven machined slots, six of which are equally spaced 60 degrees apart. The seventh slot is spaced 10 degrees after one of the 60 degree slots. The CKP sensor produces seven pulses for each revolution of the crankshaft. The pulse from the 10 degree slot is known as the sync pulse. The sync pulse is used to synchronize the coil firing sequence with the crankshaft position. The CKP sensor is connected to the PCM by a signal circuit and a low reference circuit. Page 9977 OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 592 Abbreviations And Meanings Part 4 Page 2792 Various symbols in order to describe different service operations. Page 12013 WA519F/12 - WA519F/12 Page 8369 Equivalents - Decimal And Metric Part 3 Arrows and Symbols ARROWS AND SYMBOLS Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation DOOR AJAR INDICATOR DESCRIPTION AND OPERATION DOOR AJAR INDICATOR SYSTEM COMPONENTS The door ajar indicator system consists of the following components. The driver door module (DDM) - The passenger front door module (PDM) - The body control module (BCM) - The instrument panel cluster (IPC) - The driver information center (DIC) - The driver door ajar switch - The passenger door ajar switch - The left rear door ajar switch - The right rear door ajar switch DRIVER DOOR AJAR AND PASSENGER DOOR AJAR The DDM and PDM receive a discrete input from the respective door ajar switch to indicate the status of the door. The DDM or PDM then communicates this status to the IPC via class 2 message. The IPC, upon receipt of this class 2 message, will illuminate the appropriate door ajar message in the DIC and also send a class 2 message to the radio to activate the door ajar audible warning when the following conditions are met: The transmission is removed from PARK - The vehicle speed is greater then 8.05 km/h (5 mph) LEFT REAR DOOR AJAR AND RIGHT REAR DOOR AJAR The BCM receives a discrete inputs from both the left and right rear door ajar switches to indicate the status of the doors. The BCM then communicates this status to the IPC via class 2 message. The IPC, upon receipt of this class 2 message, will illuminate the appropriate door ajar message in the DIC and also send a class 2 message to the radio to activate the door ajar audible warning when the following conditions are met: The transmission is removed from PARK - The vehicle speed is greater then 8.05 km/h (5 mph) Page 7135 Application Table Part 4 Location View Ignition System - MIL ON/Misfire DTC's In Wet Weather Cowl Moulding / Trim: Customer Interest Ignition System - MIL ON/Misfire DTC's In Wet Weather Bulletin No.: 06-06-04-048B Date: January 12, 2007 TECHNICAL Subject: 4.2L LL8 Engine - Flashing and/or MIL/SES Light, Rough Idle, Misfire(s) DTC(s) P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Install AIP Seal) Models: 2004-2007 Buick Rainier 2002-2007 Chevrolet TrailBlazer 2002-2007 GMC Envoy 2002-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X with Vortec(TM) 4.2L Inline 6 Cylinder Engine (VIN S - RPO LL8) Supercede: This bulletin is being revised to add the new part numbers for the Spark Plugs and Ignition Coils. Please discard Corporate Bulletin Number 06-06-04-048A (Section 06 - Engine/Propulsion System). Condition Some customers may comment that, after severe weather that includes large amounts of rain in a short period of time, the engine has a rough idle and/or flashing MIL/SES light. Upon further investigation, there may be the following DTC(s): P0300, P0301, P0302, P0303, P0304, P0305 or P0306. This condition can be aggravated if the vehicle is parked nose down on an incline during this type of weather. The customer may also comment on repeat occurrences of this condition because water may be passing over the Air Intake Plenum (AIP). Cause The dripping rain water onto the engine cam cover will collect at the coil(s) and may seep past the coil(s) into the spark plug(s) well of the cylinder head and may affect the operation of the spark plug(s) and coil(s), causing the misfire(s). Correction Before replacing the AIP seal, refer to Misfire diagnostics in SI to determine if water intrusion was the cause of the misfire. Diagnostic Aids for Misfire Refer to SI for Base Engine Misfire without Internal Engine Noises. If no trouble found (NTF) using SI document on Base Engine Misfire without Internal Engine Noises, then refer to SI for Misfire DTC(s). If Misfire diagnostic leads to the removal of the coil(s) and spark plug(s), refer to the following SI Documents: Air Cleaner Outlet Resonator Replacement Ignition Coil Replacement Removal Procedure Spark Plug Replacement Coil(s) damage from water intrusion will have a film of white chalk build-up on the outside and inside of the spark plug boot to ignition coil(s) assembly. If present, remove the spark plug(s) and inspect for similar build-up on the outside of the spark plug(s). If NTF with the coil(s) and spark plug(s), continue on with the Misfire Diagnostic in SI. Replace any coil and spark plug that has been diagnosed to be damaged from water intrusion. To prevent a reoccurrence, follow repair information outlined in this bulletin to replace the AIP seal. Page 7090 C201 Part 2 Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the protective cover from the underhood fuse block. 2. Remove the compressor relay (1) from the underhood fuse block (2). INSTALLATION PROCEDURE 1. Install the compressor relay (1) to the underhood fuse block (2). 2. Install the protective hood to the underhood fuse block. A/C - Intermittently Inoperative/Poor Performance Control Module HVAC: Customer Interest A/C - Intermittently Inoperative/Poor Performance Bulletin No.: 02-01-39-005A Date: August 17, 2005 TECHNICAL Subject: HVAC System Inoperative For A Drive Cycle, Poor HVAC System Performance In High Ambient Temperatures (Update HVAC Control Module Software) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL 2002-2003 Oldsmobile Bravada Supercede: This bulletin is being revised to correct the RPO usage information below: RPO CJ2 = HVAC System Air Conditioner Front, Automatic Temperature Control, Auxiliary Temperature Control RPO CJ3 = HVAC System Air Conditioner Front, Manual Temperature Control, Auxiliary Temperature Control Please discard Corporate Bulletin Number 02-01-39-005 (Section 01 - HVAC). Condition Some customers may comment about no cold air from the heating, ventilation and air conditioning (HVAC) system during a drive cycle. This concern may occur at any time during the drive cycle and at any temperature setting. The HVAC system operation returns to normal after the vehicle has been keyed to off and restarted. This concern is intermittent and most likely to occur on hot days. This concern may be found on vehicles equipped with manual (CJ3) and automatic (CJ2) HVAC systems. Other customers may comment about poor HVAC system performance in high ambient temperature conditions. This concern may be present in automatic (CJ2) HVAC systems only. An HVAC control module software update was put into all production vehicles beginning in September 2002. Vehicles built in September 2002 and earlier may need this software update. Correction Update the HVAC control module using software available through GM Access beginning September 9, 2002. The update will be fully available October 7, 2002 to all dealers on TIS 2000 CD version 10. This software update addresses both the intermittent no cooling and the poor performance concerns. If the software update does not correct the concerns, perform the HVAC Diagnostic System Check and repair as necessary. If the HVAC control module is replaced with a part from GMSPO, make sure the module has the latest software update. The module may need to be updated even though it is a new part. Warranty Information Disclaimer Page 7757 For vehicles repaired under warranty, use the table. Disclaimer Page 1622 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Page 10536 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 1267 before servicing. 6. Install the J 43600 ACR 2000 Air Conditioning Service Center. Important: ^ The ambient temperature must be at least 16°C (60°F). ^ Do not induce additional air flow across the front of the vehicle during the test. 7. Record the ambient temperature displayed on the J 43600. 8. Record readings of the low and high side STATIC pressures. The pressures should be within the specifications listed below. ^ Above 16°C (60°F): 345 kPa (50 psi) ^ Above 24°C (75°F): 483 kPa (70 psi) ^ Above 33°C (90°F): 690 kPa (100 psi) ^ If the static pressures are within specification, continue with Step 12. ^ If the static pressures are NOT within specifications, refer to Leak Testing (SI Document ID # 1141201). 9. Apply the parking brake. 10. Place the transaxle/transmission in PARK. 11. Start the engine. 12. Turn on the A/C system. 13. Inspect the A/C compressor to see if it is operating properly. 14. If the compressor is not operating as designed, tap on the low pressure cycling switch (2) with a small hand tool. The compressor should start operating correctly. 15. If the compressor does not operate correctly after tapping on the low pressure cycling switch (2), disconnect the switch and jumper the lower pressure cycling switch connector with a fused jumper. If the compressor still does not operate properly, refer to HVAC Compressor Clutch Does Not Engage diagnostic in SI. Important: DO NOT USE A/C low pressure cycling switch, P/N 15035084 on the vehicles listed above. 16. If the compressor does operate correctly after tapping on the switch or jumping the low pressure cycling switch connector, replace the low pressure cycling switch (2), P/N 89040362. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement in SI. 17. Perform the Air Conditioning (A/C) System Performance Test in SI. Page 12411 2. Install the seat switch to the seat bezel assembly. Verify that the retaining tabs are fully seated. 3. Install the buttons on the switch. 4. Install the switch bezel assembly to the seat assembly. Page 6220 Abbreviations And Meanings Part 19 Locations Engine, Left Side Page 5070 Disclaimer Page 4435 Engine Oil Level And Temperature Sensor Page 6188 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 5115 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 5331 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. ^ Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. Page 7434 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 7936 ^ The LH and RH springs are not necessarily the same part numbers. ^ Each vehicle may have a different build combination. ^ Use the RPO label located in the glove box to determine what part number springs to replace. ^ Only small quantity of parts are available. Please DO NOT order for stock only. 1. Select the correct new rear coil spring part numbers. Refer to the Parts Information below. 2. Install the upper bushing seats on the new rear coil springs and install the springs into the vehicle. 3. Raise the rear axle with the adjustable jack stand. 4. Install the two shock absorber lower mounting bolts. Tighten Tighten the two shock absorber lower mounting bolts to 80 N.m (59 lb-ft). 5. Remove both of the adjustable jack stands from under the vehicle. 6. Lower the vehicle. Parts Information Warranty Information Page 3447 Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Control Module: All Technical Service Bulletins Engine Controls - Hesitation/Stall/Harsh A/T Upshifts Bulletin No.: 03-06-04-057 Date: October 01, 2003 TECHNICAL Subject: Intermittent Hesitation, Stumble or Idle Stall after Soak, Harsh 1-2 Shift, Slipping 1-2 Shift Followed by a Harsh Engagement (Reprogram PCM) Models: 2002-2003 Chevrolet TrailBlazer 2002-2003 GMC Envoy 2002-2003 Oldsmobile Bravada with 4.2L Engine (VIN S - RPO LL8) Condition Some customers may comment on an intermittent hesitation/stumble or idle stall within minutes of starting after the vehicle has been sitting for several hours. Additionally, some customers with a 2003 model year vehicle may comment on a harsh 1-2 shift or 1-2 slip shift that has a bump feeling when 2nd gear engages. Cause This condition may be caused by the EVAP diagnostic test as it opens the purge valve for a few seconds and then closes it to verify proper emission sensor operation. If the purge canister is saturated, the EVAP system on-board diagnostic test may cause the vehicle to correct for a rich condition from the canister. The vehicle would then become lean when the purge valve closes at the completion of the test. This condition occurs primarily with high RVP fuel and after the vehicle sits for several hours in a warm ambient, above 21°C (70°F). A customer who takes short trips is more likely to experience this condition, as they don't have the drive cycle that would allow the purge canister to fully re-circulate the fuel vapor. Correction For Hesitation, Stumble or Idle Stall: Follow the SI diagnostics for the stall/stumble condition. If the result is no trouble found, then reprogram the module with the latest calibration. For Harsh or Slipping Shifts on 2003 Model Year vehicles: Reprogram the module with the latest calibration. The calibrations listed are electronic calibrations and are NOT available from GMSPO. Calibrations will be available from Techline starting September 2003, on the TIS 2003 Disc 10.0 CD ROM. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation shown. Page 12077 WA882K/90 - WA900J/59 Page 222 Specifications Compression Check: Specifications Record the compression readings from all of the cylinders. A normal reading should be approximately 1482 kPa (215 psi). The lowest reading should not be less than 70 percent of the highest reading. Page 2711 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 4577 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Page 10020 Page 2432 8. Lower the Vehicle. Page 6944 Location View Page 8509 HVAC Control Module-Auxiliary (Body Type VIN 3) Part 2 OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 11660 34. Disconnect the electrical connector from the right-hand body side window actuator. 35. Disconnect the electrical connector from the left-hand body side window actuator. 36. Remove the windshield rearview mirror wire harness cover. 37. Disconnect the inside rear view mirror electrical connector (3). 38. Disconnect the rain sensor electrical connector (2), if equipped. 39. Disconnect the coax cable (1) from the navigational antenna, if equipped. 40. Remove the bolt securing the auxiliary air conditioning duct to the vehicle. 41. Remove the 2 push pins (2,3) from the rear of the headliner. 42. Remove the 3 push pins from the rear of the headliner. 43. Release the assist handles from the roof panel. Refer to Assist Handle Replacement. 44. With the aid of an assistant, lower the headliner to release the interlocking strips (1) that retain the headliner to the roof panel. Page 633 Mirror Connector, Front Passenger Door Module (FPDM) - C3 Part 2 Body - Front Bumper Fascia Panel Wavy Front Bumper Cover / Fascia: Customer Interest Body - Front Bumper Fascia Panel Wavy Bulletin No.: 02-08-62-004B Date: June 02, 2006 TECHNICAL Subject: Front Fascia Wavy (Install Dual Lock) Models: 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet TrailBlazer EXT LS Model 2006-2007 Chevrolet TrailBlazer LS, TrailBlazer SS Supercede: This bulletin is being revised to add model years and material allowance. Please discard Corporate Bulletin Number 02-08-62-004A (Section 08 - Body and Accessories). Condition Some customers may comment that the front fascia is wavy under the grille or under the front turn signals. Refer to the illustration above. Correction 1. Remove the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. 2. Remove the impact bar from the front fascia. 3. Remove the hot melt on the top of the impact bar. 4. Clean and scuff the impact bar with a scotch bright pad. 5. Apply a coating of GM Adhesion Promoter, P/N 12378462 (Canadian P/N 10953554), to the top surface of the impact bar and let dry. 6. Install 3M Dual Lock, P/N 06463, to the impact bar as shown in the illustration above. 7. Clean the fascia and apply the Adhesion Promoter to the fascia. 8. Install the impact bar to the fascia. 9. Install the front fascia. Refer to the Fascia Replacement procedure in the Bumpers sub-section of the Service Manual. Page 12447 6. Remove the seat cover J-strips (1) from the seat cushion trim panel (2). 7. Remove the screws securing the seat cushion trim panel to the seat frame. 8. Remove the seat cushion trim panel. INSTALLATION PROCEDURE 1. Install the screws securing the seat cushion trim panel to the seat cushion assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat cushion trim panel screws to 2 N.m (18 lb in). Page 2927 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 460 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 13452 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the pushrod retainer (3) from the brake pedal pin (4). 2. Remove the stop lamp switch (1) and the pushrod (2) from the brake pedal pin (4). 3. Disconnect the stoplamp switch (1) electrical connector. 4. Remove the stoplamp switch from the vehicle. INSTALLATION PROCEDURE 1. Install the electrical connector to the stop lamp switch (1). 2. Position the stop lamp switch (1) on the pushrod (2) and install the assembly on the brake pedal pin. 3. Install the pushrod retainer (3) to the brake pedal pin (4). The retainer will snap into place. Page 4942 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................. AC 41-981 A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 9829 Abbreviations And Meanings Part 21 Page 13943 Abbreviations And Meanings Part 13 Page 7277 Abbreviations And Meanings Part 13 Page 11437 Quarterglass Switch - L Electrical - Intermittent Interior Electrical Concerns Control Assembly: Customer Interest Electrical - Intermittent Interior Electrical Concerns File In Section: 08 - Body and Accessories Bulletin No.: 04-08-45-010 Date: September, 2004 TECHNICAL Subject: Various Interior Electrical Concerns, IP Gauges/Lighting Inoperative, HVAC Controls Inoperative, Blower Motor Inoperative, Radio Inoperative, Flasher Inoperative (Repair Ground 201) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2005 GMC Envoy, Envoy XL 2004-2005 GMC Envoy XUV 2002-2003 Oldsmobile Bravada Condition Some customers may comment on intermittent operation of various electrical components in the interior of the vehicle. Components that can be affected are not limited to the list that follows: ^ IP Gauges/Lighting Inoperative ^ HVAC Controls Inoperative ^ Blower Motor Inoperative ^ Radio Inoperative ^ Flashers Inoperative ^ Transfer Case Shift Controls Inoperative Service information ground distribution schematics should be reviewed for complete detail of items grounded at G201. Cause The cause of these conditions may be a loose or ineffective connection at ground splice pack G201 located on the right side of the front console area. Correction Repair the ground splice pack G201 connection using the procedure listed below. 1. Remove the center floor console. 2. Remove the 4 screws that retain the instrument panel (IP) lower closeout carpet panel to the IP substrate. 3. Remove the IP lower closeout carpet panel. 4. Remove the ground splice pack G201 bolt. If the bolt shows any sign of discoloration, clean the bolt using a wire brush. 5. Remove any carpet that may have been trapped during assembly. Clean the ground surface on the body using an emery cloth. 6. Install the IP lower closeout carpet panel. 7. Install the 4 screws that retain the IP lower closeout carpet panel to the IP substrate. 8. Install the center floor console. Page 10178 Page 13782 Turn Signal/Multifunction Swtich C3 Page 10135 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 7275 Abbreviations And Meanings Part 11 Page 7466 C109 Page 29 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 1005 40.1. Install the ring terminal (black wire) to ground G103 (1), located on the right side inner tender. 40.2. Route the pump wiring harness along the existing right side forward lamp harness. 40.3. Connect the electrical connectors to the coolant bypass valve (1) and auxiliary heater pump (2). 40.4. Position the relays onto the inner wheelhouse panel near the rear of the engine compartment. Page 3683 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 4264 English Prevailing Torque Fastener Minimum Torque Development Part 1 Page 1753 Abbreviations And Meanings Part 17 Page 11678 4. Ensure the top of the roof panel tab (2) is positioned over the plastic retaining tab (1). 5. Using a flat bladed tool, carefully push up on the bottom of the front roof panel tab (1) until fully seated. 6. Using a flat bladed tool, carefully push on the bottom of the rear roof panel tab until fully seated. 7. Close the bezel covers. 8. Pull downward on the assist handle to ensure the handle is fully secured to the roof panel. Page 10036 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 6651 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 10764 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 3894 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Description and Operation Security Lamp/Indicator: Description and Operation SECURITY INDICATOR The instrument panel cluster (IPC) illuminates the SECURITY indicator as determined by the vehicle theft deterrent (VTD) system. The IPC receives a message via the serial data circuit from the theft deterrent control module requesting illumination. The VTD system requests the IPC to illuminate the indicator only when the ignition is ON. The VTD system uses the indicator as a malfunction indicator. For vehicle theft deterrent (VTD) information, refer to Vehicle Theft Deterrent (VTD) Description and Operation. The SECURITY indicator on the instrument cluster is controlled by both the VTD system and the CTD system. The SECURITY indicator is an LED on the instrument cluster which illuminates the word SECURITY. The SECURITY indicator is controlled by the body control module grounding the security indicator control circuit. The VTD system commands the instrument cluster to control the indicator only when the ignition switch is ON. The VTD system uses the indicator as a malfunction indicator. - The CTD system commands the instrument cluster to control the indicator only when the ignition switch is OFF. The CTD system uses the indicator to identify system status. SECURITY INDICATOR OPERATION The theft deterrent control module can command the instrument cluster to illuminate the SECURITY indicator only when the ignition key is in the ON position. If the PCM loses communication with the theft deterrent control module, the instrument cluster will also detect the loss of communication and will illuminate the SECURITY indicator. The SECURITY indicator can indicate both malfunctions, Indicator on steady and tamper, Indicator flashing. A flashing indicator indicates unauthorized operation. Under the following conditions the SECURITY indicator may be commanded to illuminate. SECURITY Indicator Illuminates when Engine is Running If the theft deterrent control module is unable to measure the ignition key transponder value or the PCM loses communication with the theft deterrent control module while the engine is running, the indicator will be illuminated. SECURITY Indicator Illuminated and Engine Does Not Start If the theft deterrent control module was unable to measure the ignition key transponder value or the PCM has detected a problem with the theft deterrent system. The VTD system is in Learn Mode. Refer to Programming Theft Deterrent System Components. SECURITY Indicator Flashes and Engine Does Not Start The theft deterrent control module has measured an incorrect transponder value, the calculation to the challenge is incorrect or the PCM has lost communication with the theft deterrent control module, The VTD system considers this a tamper condition. The VTD indicator will flash. Page 9375 Abbreviations And Meanings Part 9 Page 10886 Abbreviations And Meanings Part 22 Page 9336 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 8465 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9261 Global Positioning System Antenna: Service and Repair Navigation Antenna Replacement NAVIGATION ANTENNA REPLACEMENT REMOVAL PROCEDURE 1. Ensure the ignition is in the OFF position. 2. Remove the electrical connector from the antenna. 3. While maintaining a parallel angle to the windshield, remove the antenna from the bracket by sliding the antenna away from the headliner. INSTALLATION PROCEDURE 1. Position the antenna to the bracket. 2. While maintaining a parallel angle to the windshield, install the antenna to the bracket by sliding the antenna towards the headliner. Ensure the antenna is fully seated to the bracket. 3. Install the electrical connector to the antenna. Page 6107 Electronic Brake Control Module: Specifications EBCM to BPMV 39 inch lbs. Page 6467 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement Master Cylinder Reservoir Replacement Removal Procedure Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Remove the brake master cylinder assembly. 2. Drain the brake fluid from the reservoir. Notice: Do not clamp on the master cylinder body. Doing so may damage the master cylinder. 3. Clamp the flange of the master cylinder body in a vise. 4. Remove the retaining pins for the brake master cylinder reservoir. Page 5821 3. Install the pinion yoke. Align the marks made during removal. Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut. 6. Install the J8614-01 onto the pinion yoke as shown. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 7. Tighten the pinion nut while holding the J8614-01. Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Page 9301 Passlock Sensor Page 9492 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 11618 Console Replacement Removal Procedure 1. Block the wheels to prevent the vehicle from moving. 2. Remove the rubber ash tray inserts and rubber mat from the console. 3. Remove the floor shift control knob. 4. Remove the center console shift lever bezel, Oldsmobile only. 5. Remove the console storage compartment. 6. Remove the center console retaining screws. 7. Adjust the parking brake to the full-up, or fully engaged position. 8. Release the 2 forward trim extensions ears attached to the lower IP-Oldsmobile only. 9. Slide the console rearward and raise the rear of the console in order to expose the electrical connectors. 10. Disconnect the electrical connectors as necessary. 11. Adjust the parking brake to approximately the halfway position. 12. Remove the center console from the vehicle. Installation Procedure 1. Position the center console to the vehicle. 2. Adjust the parking brake to the full-up, or fully engaged position. 3. Connect the electrical connectors as necessary. 4. Lower the rear of the console and slide the console forward into position. 5. Ensure that the 2 retaining ears on the front extensions of the console are fully engaged to the lower IP-Oldsmobile only. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the center console retaining screws. Tighten the screws to 2.5 N.m (22 lb in). 7. Install the console storage compartment. 8. Install the center console shift lever bezel 9. Install the floor shift control knob. 10. Install the rubber ash tray inserts and rubber mat to the console. 11. Remove the bocks from the vehicle. Console Storage Bin Replacement Page 7368 Application Table Part 3 Location View Page 6261 1. If the brake caliper guide pin is to be reused, clean the brake caliper guide pin using denatured alcohol, or equivalent. 2. Dry the brake caliper guide pin using non-lubricated, filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper guide pin. DO NOT apply lubricant to the brake pad hardware. 4. Install the front brake caliper to the mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the front brake caliper mounting bolts. ^ Tighten the front brake caliper mounting bolts to 51 Nm (38 ft. lbs.). Important: DO NOT reuse the metal/copper gaskets. Use only new metal/copper gaskets. 6. Install the NEW metal/copper gaskets to the front brake caliper bolt. 7. Install the front brake hose bolt and gaskets. ^ Tighten the brake hose bolt to 54 Nm (40 ft. lbs.). 8. Bleed the hydraulic brake system. 9. Install the tire and wheel assembly. 10. Lower the vehicle. Refer to Vehicle Lifting. Rear Brake Caliper Replacement - Rear Page 893 Body Control Module (BCM) C1 Part 3 Page 10382 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION RETAINED ACCESSORY POWER (RAP) POWER MODE RAP is a power mode that permits the operation of selected customer convenience items for 10 minutes after the ignition switch is turned OFF. RAP power mode is enabled by the BCM. The BCM: controls certain body functions. - sends out a class 2 message via the serial data line, which enables/disables other modules at the beginning/end of RAP power mode. Some BCM features, such as the interior courtesy lamps will function after the 10 minute RAP time limit has elapsed. This is normal, and does not mean RAP power mode is malfunctioning. The BCM enables the following functions in RAP Power Mode: The sunroof (internal to BCM - if equipped) - The right and left power rear windows (internal to BCM - if equipped) - Any class 2 module that functions in RAP power mode (that is not hard-wired), is controlled by the BCM via class 2 power mode messages. EXAMPLE: the radio works in RAP power mode due to the BCM allowing and controlling it. RAP is disabled when: The door is opened. - A low battery voltage is detected by the BCM. - The transition of ignition switch from OFF to ON or ACC. - 10 minutes have elapsed after the ignition was turned OFF. - There may be some functions of the vehicle that are hard-wired straight to the battery, these are the exceptions. The BCM monitors the ignition switch position, battery voltage and passenger compartment door status to determine whether RAP power mode should be enabled. If the ignition switch transitions from ON to OFF, the battery voltage is within the acceptable range and the passenger compartment doors are closed, the BCM enables RAP power mode. After the 10 minutes has elapsed, the BCM sends a class 2 message to the serial data network. This message commands the other modules to stop functioning, that are power moded by the BCM. RAP RELAY (IF EQUIPPED) The long base vehicles (GMT370), with third row seating, will have a RAP relay (RAP relay is also on the G/H Van). Due to this, the BCM will power/enable a relay. On the short based vehicles (GMT360), the RAP output only needs to drive the sunroof. The BCM is able to supply enough current to operate the sunroof by itself, so a relay is not needed. Although, on the GMT370/longbase vehicle, there are optional powered rear quarter vent windows, which are also enabled in RAP power mode. Refer to Retained Accessory Power (RAP) Schematics for the applicable schematics for RAP on both vehicle types. On the GMT370/longbase vehicle, the BCM is not able to supply enough current to both rear quarter vent windows and the sunroof at the same time (if equipped with both options). This is the purpose of the RAP relay. The BCM energizes the RAP relay coil, which allows a fused power supply to the sunroof and the rear quarter vent windows. Page 12440 1.2. Remove the 3 trim panel retaining screws. 2. Remove the trim panel from the manual seat by performing the following steps: 2.1. Remove the lumbar support knob. 2.2. Remove the seat back recliner handle. 2.3. Remove the screws from the trim panel. 3. Remove the trim panel from the seat assembly. INSTALLATION PROCEDURE 1. Install the trim panel to the power seat by performing the following steps: Page 3173 16. Remove the nut and bolt securing the coolant recovery reservoir. 17. Remove the coolant recovery reservoir with the accumulator attached. 18. Remove the evaporator tube nut at the evaporator. 19. Remove the evaporator tube from the evaporator 20. Using the J 43181, disconnect the heater hoses from the core. 20.1. Install the J 43181 to the heater core hose. 20.2. Close the tool around the heater core hose. 20.3. Firmly pull the tool into the quick connect end of the heater hose. 20.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 21. Disconnect the coolant bypass valve hose from the auxiliary rear heater line. 22. Disconnect the coolant bypass valve hose from the engine. 23. Disconnect the electrical connector from the coolant bypass valve. This connector will no longer be used. Tape off with electrical tape. 24. Disconnect the vacuum hose from the coolant bypass valve. 25. Remove the nut retaining the coolant bypass valve to the cowl and remove the coolant bypass valve with hoses attached. 26. Remove the heater hose quick connect retainers from the heater core pipes. 27. Remove the four nuts and the HVAC plate from the dash panel. 28. Attach the new auxiliary heater pump to the new bracket using the supplied retainers as shown. Note the position of the pump on the bracket. Page 6106 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 12559 Abbreviations And Meanings Part 27 Registered And Non-Registered Trademarks REGISTERED AND NON-REGISTERED TRADEMARKS Registered And Non-Registered Trademarks Part 1 Page 10903 Body Control Module (BCM) C3 Part 1 General Overview Page 1938 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................................. AC 41-981 Page 9997 Page 11727 Tighten the anchor bolt to 70.0 N.m (52 lb ft). 12. Install the right rear door sill panel. 13. Install the liftgate sill plate. 14. Install the trim panel-rear quarter upper. Trim Panel Replacement - Rear Quarter Upper TRIM PANEL REPLACEMENT - REAR QUARTER UPPER (TRAILBLAZER, ENVOY, BRAVADA) REMOVAL PROCEDURE 1. Remove the cargo shade/cover. 2. Remove the screw that retains the trim panel to the body. 3. Remove the cargo net retaining knobs. 4. Remove the bolt that retains the seat belt upper guide to the body. 5. Remove the rear upper quarter trim panel from the vehicle. INSTALLATION PROCEDURE 1. Install the rear upper quarter trim panel to the vehicle. 2. Install the seat belt retractor to the body. 3. Install the bolt that retains the rear seat belt upper guide to the body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat belt upper guide shoulder bolt to 70 N.m (52 lb ft). 4. Install the screw that retains the rear upper quarter trim panel to the body. Tighten Tighten the rear upper quarter trim panel screw to 2 N.m (18 lb in). 5. Install the cargo net retaining knobs. Page 2212 Fuse Block - Rear C1 Part 2 Page 13671 service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers, possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in Page 7848 8. Remove the rear axle upper control arm to frame mounting bolt. 9. Remove the rear axle upper control arm. Installation Procedure 1. Install the rear axle upper control arm. 2. Install the rear axle upper control arm to frame mounting bolt. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear axle upper control arm to axle mounting nut and bolt. Tighten the rear axle upper control arm mounting bolts to 130.5 Nm (96 ft. lbs.). 4. If equipped with air suspension, connect the air suspension leveling sensor link to the rear axle upper control arm. Page 6781 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Page 10646 Page 1994 Disclaimer Page 8227 Recirculation Actuator Page 2770 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 12439 3. Install the seat cushion cover and pad to the seat frame. 4. Install the 4 nuts that secure the seat pan to the power seat adjuster frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat pan mounting nuts to 25 N.m (18 lb ft). 5. Install the seat harness to the seat pan. 6. Install the SIR harness (2) to the seat clips (1, 4). 7. Connect the gray lumbar electrical connector (5), if equipped. 8. Connect the black electrical connector (3) to the seat belt buckle. 9. Connect the black electrical connector (6) to the seat back harness. 10. Install the 3 seat switch bezel mounting screws. Seat Cushion Outer Trim Panel Replacement SEAT CUSHION OUTER TRIM PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the trim panel from the power seat by performing the following: 1.1. Remove the 3 seat switch bezel mounting screws. Page 1726 Various symbols in order to describe different service operations. Page 4046 Powertrain Control Module (PCM) C3 Part 2 Page 8683 Disclaimer Instruments - Erratic Speedometer Operation Engine Control Module: Customer Interest Instruments - Erratic Speedometer Operation Bulletin No.: 07-08-49-027 Date: December 04, 2007 TECHNICAL Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Models: 2004-2007 Buick Rainier 2002-2008 Chevrolet TrailBlazer Models 2002-2008 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005-2008 Saab 9-7X with 4.2L Engine Only (VIN S - RPO LL8) Condition Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108. Correction Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information. Warranty Information (excluding Saab U.S. Models) Page 8098 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 9027 5. Install the anchor bolt cover. 6. Install the rear quarter upper trim, left or right side. 7. Install the rear seat belt upper guide with the bolt. Ensure that the seat belt webbing is not twisted. Tighten Tighten the rear seat belt upper guide bolt to 70 N.m (52 lb ft). Page 3873 Page 9742 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Page 9102 5. Loosen the bolts (1) retaining the sensor to the frame. 6. Remove the sensor assembly from the frame (1). 7. Position the sensor assembly above the front bumper. 8. Remove the retaining bolts and protective cover (1) from the sensor. 9. Remove the connector-position assurance (CPA) from the sensor electrical connector. 10. Disconnect the sensor (2) electrical connector. 11. Remove the sensor from the vehicle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Page 1967 Drive Belt Chirping Diagnosis Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Page 1439 Heated Oxygen Sensor (HO2S) 1 Page 13934 Abbreviations And Meanings Part 4 Page 966 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Page 4902 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Page 3748 Steps 8-9 Page 10483 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 8512 HVAC Control Module-Auxiliary, With Rear Seat Audio (Body Type VIN 6) Part 3 HVAC System - Automatic Locations Accelerator Page 12731 4. Install the front door sill plate. Page 8896 4. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 5. Remove the LF door trim panel. 6. Remove the connector position assurance (CPA) (3) from the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. 7. Disconnect the side impact sensor yellow 2-way connector (5) located near the bottom left of the door. Zone 3 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Disabling and Enabling Zones before disabling the SIR system. 2. Turn OFF the ignition. 3. Remove the key from the ignition. 4. Remove the trim panel. Page 5870 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Page 3292 Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove the heater core access cover screws. 3. Remove the heater core access cover. 4. Remove the heater core (2) from the HVAC module assembly (1). INSTALLATION PROCEDURE 1. Install the heater core (2) to the HVAC module assembly (1). 2. Install the heater core access cover. 3. Install the heater core access cover screws. Tighten the screws to 1.9 N.m (17 lb in). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the HVAC module assembly. Page 12280 5. Using a glue gun, hot melt the electrical connectors (1) to the headliner substrate, ensuring the connectors are securely attached to the substrate. 6. Route the wire harness until fully seated into the sunshade wire harness channel located on the pivot arm. Important: If the wire harness retaining clip is removed from the sunshade for any reason, a new retaining clip must be installed. Page 7155 7. Remove the junction block bracket retaining bolts (1) and remove the junction block bracket from the vehicle. INSTALLATION PROCEDURE 1. Position the junction block bracket and install the bolts (1). Tighten Tighten the junction block bracket bolts to 6 N.m (53 lb in). 2. Align the wiring harnesses and install the fuse relay center. 3. Install the fuse relay center bolts (3). Tighten Tighten the relay center bolts to 6 N.m (53 lb in). Page 10423 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 5747 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tighten the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Page 3113 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Page 9477 Disclaimer Page 6279 Brake Pad: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Caution: Refer to Brake Dust Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Diagrams Oil Level Sensor For ECM: Diagrams Engine Oil Level and Temperature Sensor Page 11894 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 2 screws that retain the actuator (1) to the lock. Tighten the screws to 0.75 N.m (6 lb in). 5. Install the lock to the door. 6. Install the water deflector. 7. Install the door trim panel. Lock Actuator Replacement - Rear Door Lock Actuator Replacement - Rear Door Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the door latch assembly. 4. Remove the 2 screws that retain the actuator (1) to the lock. 5. Simultaneously lift up on and rotate the actuator away from the latch in order to disengage the rubber bumper (1) from the latch. 6. Remove the actuator from the latch. Installation Procedure Page 1333 Miniwedge (Door Jamb Switch) - RF Page 9780 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Data for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Page 7567 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Specifications Lateral Stabilizer Rod: Specifications Rear Axle Brace to the Frame Mounting Nut 70 ft. lbs. Rear Axle Brace and Rear Axle Tie Rod to Rear Axle Mounting Nut 144 ft. lbs. Rear Axle Tie Rod Mounting Bolts 144 ft. lbs. Page 9968 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Transmission Extension Housing Rear Oil Seal Replacement Seals and Gaskets: Service and Repair Transmission Extension Housing Rear Oil Seal Replacement Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 21426 Extension Housing Seal Installer - J 36850 Transmission Assembly Lubricant Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 21426 with a soft faced mallet to install the seal. 3. Install the seal to the extension housing. 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position variation learn procedure. 4. The scan tool instructs you to perform the following items: - Accelerate to wide open throttle (WOT). - Release the throttle when fuel cut-off occurs. - Observe the fuel cut-off for the engine that you are performing the learn procedure on. - The engine should not accelerate beyond calibrated RPM value. - Release the throttle immediately if value is exceeded. - Block the drive wheels. - Set the parking brake. - DO NOT apply the brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle the engine. - Turn the A/C OFF. - The vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. With the scan tool, enable the crankshaft position system variation learn procedure. 6. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 7. Release the throttle when the fuel cut-off occurs. 8. The scan tool displays Learn Status-Learned this ignition: - If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. - If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. - If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The crankshaft position system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P1336 sets: Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - Crankshaft position sensor replacement - Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship. Page 10518 Page 562 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 9841 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 7351 Fuse Block - Underhood C2 Part 2 Page 7599 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 12131 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Repairing Connector Terminals Page 2429 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Step 1 - 4 Wheel Bearings Diagnosis Step 5 - 7 Page 12308 Sunroof Module Page 8350 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 5567 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13630 Headlamp Switch C2 Page 8618 1. Apply coolant to the end of the heater inlet hoses. 2. Install the heater inlet hose to the inlet hose fitting at the engine block. IMPORTANT:When installing a new heater inlet hose, place the clamps on the hose before installing the hose to the inlet hose fitting at the engine block. 3. Install the coolant bypass valve (6). 4. Install the nut retaining the coolant bypass valve to the cowl. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the nut to .....10 N.m (89 lb in). 5. Install the vacuum hose to the coolant bypass valve. 6. Install the inlet heater hose to the engine block. 7. Position the inlet heater hose clamp at the engine block using J 38185. 8. Connect the heater inlet hose to the heater core. 9. Install the coolant recovery reservoir. IMPORTANT:Firmly push the quick connect onto the heater core pipe until you hear an audible click. 10. Fill the engine cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 6)Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. Page 8238 4. Remove the rear mode actuator retaining screws. 5. Remove the rear mode actuator. INSTALLATION PROCEDURE 1. Install the mode actuator. 2. Install the screws to the mode actuator. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Page 1842 Steps 8-9 Page 6294 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Page 1304 Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the front passenger side seat. 2. Remove the park brake warning lamp switch electrical connector. 3. Remove the park brake warning lamp switch retaining screw. 4. Remove the park brake warning lamp switch from the vehicle. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch retaining screw. ^ Tighten the park brake warning lamp switch mounting bolt to 4 Nm (35 inch lbs.). 3. Connect the electrical connector. 4. Install the front passenger side seat. Page 9495 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 4355 Powertrain Control Module (PCM) C1 Part 4 Page 2230 Fuse Block - Underhood C1 Part 3 Page 11600 Carpet: Removal and Replacement Carpet Replacement - Front Carpet Replacement - Front Removal Procedure 1. Remove the front bucket seats. 2. Remove the front door sill plates. 3. Remove the center pillar trim panels. 4. Remove the floor console. 5. Remove the floor console bracket. 6. Remove the carpet from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Position the carpet to the floor panel. 2. Feed the front edge of the carpet underneath the instrument panel. 3. Align the holes in the carpet to the seat studs on the floor panel. 4. Position the rear carpet over the edge of the front carpet. 5. Install the floor console bracket. 6. Install the floor console. 7. Install the center pillar trim panels. 8. Install the front door sill plates. 9. Install the front bucket seats. Carpet Replacement - Rear (TrailBlazer EXT, Envoy XL) Carpet Replacement - Rear (TrailBlazer EXT, Envoy XL) Removal Procedure 1. Remove the front seats. 2. Remove the second row rear seats. Page 9638 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 203 Page 8373 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 8663 4. Install all of the screws to the HVAC module-auxiliary. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the mode actuator-auxiliary. 6. Install the mode actuator-auxiliary screws. Tighten Tighten the screws to 2 N.m (18 lb in). 7. Install the air temperature actuator-auxiliary. 8. Install the air temperature actuator-auxiliary screws. Tighten Tighten the screws to 2 N.m (18 lb in). 9. Install the evaporator core-auxiliary. 10. Install the blower motor-auxiliary. 11. Install the blower motor-auxiliary screws. Tighten Tighten the screws to 2 N.m (18 lb in). 12. Install the HVAC module-auxiliary. Page 13051 6. Remove the SIR fuse from the fuse block (1) located in the underhood fuse block. IMPORTANT: With the SIR fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 7. Remove the connector position assurance (CPA) (1) from the steering wheel module yellow 4-way connector (2) located left of the steering column near the knee bolster. 8. Disconnect the steering wheel module yellow 4-way connector located left of the steering column near the knee bolster. 9. Remove the CPA from the IP module yellow 4-way connector (1) located behind the IP support. 10. Disconnect the IP module yellow 4-way connector (1) located behind the IP support. Page 11824 Abbreviations And Meanings Part 9 Page 11557 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 88 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 13951 Abbreviations And Meanings Part 21 Knock Sensor (KS) 1 Front Knock Sensor (KS) 1 Front Page 13226 Page 2015 8. Install the oil level indicator. 9. Remove the oil level indicator and check the oil level. Add oil if necessary. Check for any oil leaks. Page 1473 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement REMOVAL PROCEDURE 1. Remove the camshaft position (CMP) sensor electrical connector (1). 2. Remove the CMP sensor retaining bolt. INSTALLATION PROCEDURE 1. Install the camshaft position (CMP) sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CMP sensor bolt to 10 N.m (89 lb in). 2. Install the CMP sensor electrical connector (1). Page 3751 Steps 16-19 Heated Oxygen Sensor (HO2S) 2 Heated Oxygen Sensor (HO2S) 2 Page 575 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 83 Registered And Non-Registered Trademarks Part 2 Page 8963 Side Air Bag: Service Precautions CAUTION: - Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. - Refer to SIR Caution in Service Precautions. - Following the deployment of a side impact air bag, inspect the following parts for damage. Replace these parts if necessary: The seat cushion frame - The seat recliner, if equipped - The seat adjuster - The seat back frame Failure to do so may cause future personal injury. Page 7843 7. Remove the shock module yoke lower mounting nut. 8. Disconnect the shock module yoke from the lower control arm using J24319-B. 9. Remove the lower control arm to lower control arm bracket mounting nuts. Important: Note the direction the bolts are removed for installation. 10. Remove the lower control arm to lower control arm bracket mounting bolts. Steering Gear Crossmember Replacement - Front Cross-Member: Service and Repair Steering Gear Crossmember Replacement - Front Steering Gear Crossmember Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the engine shield mounting bolts. 3. Remove the engine shield. 4. Remove the rear lower control arm bracket to frame mounting bolts. 5. Remove the steering gear crossmember mounting bolts. 6. Remove the steering gear crossmember. Installation Procedure Page 8447 Compressor Clutch: Diagrams A/C Compressor Clutch Assembly (w/Manual - HVAC System) Page 11317 Reprogram the automatic transfer case control module if necessary. Chevrolet TrailBlazer, TrailBlazer EXT Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the two (2) screws that retain the rear edge of the driver's side insulator to the IP. 2. Remove the two (2) screws that retain the bottom of the knee bolster to the IP. 3. Remove the two (2) screws that retain the top of the knee bolster to the IP. 4. Remove the four (4) screws that retain the IP bezel to the IP. 5. Separate the bezel from the IP enough to allow access to the transfer case control switch. 6. Disconnect the electrical connector and remove the switch. 7. Install the new switch and connect the electrical connector. 8. Reposition the IP bezel and install the four (4) retaining screws. 9. Reposition the knee bolster and install the four (4) retaining screws. 10. Reposition the insulator and install the two (2) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Reprogram the automatic transfer case control module if necessary. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9023 1. Position the seat belt retractor bracket on the seat back frame. 2. Install the seat belt retractor bracket bolt (1) to the bracket and seat back frame. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt retractor bracket bolt to 55 N.m (40 lb ft). 3. Position the seat belt retractor assembly onto the seat back frame. Install the push pin (2) on the seat back retractor to the seat back frame. 4. Install the lower seat belt retractor bolt. Tighten Tighten the lower seat belt retractor bolt to 55 N.m (40 lb ft). Page 302 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 7152 Location View Page 2872 6. Install the crankcase ventilation hose. 7. Install the MAP sensor electrical connector. 8. Install the engine harness bracket. Secure the bracket with the bolt. Tighten the engine harness bracket bolt to 50 Nm (37 ft. lbs.). 9. Install the front differential vent hose to the engine harness bracket clip. 10. Install all harnesses to the original location onto the engine harness bracket. 11. Install the PCM. 12. Install the throttle body. Page 12973 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Page 453 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 13998 Important: The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 3.1.1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 3.1.2. Repeat the process for the passenger side and center area zones. 3.1.3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2. Method using portable infrared thermometer: 3.2.1. Start the engine and turn on the rear back window defogger. 3.2.2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3.2.3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2.4. Repeat the process for the passenger side and center area zones. 4. Use Permatex(R) Quick Grid, GM P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C - 371°C (500°F - 700°F). Hold the heat gun within 25 - 51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Disclaimer Page 888 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 8634 block. 3. Position the inlet heater hose clamp (1) at the engine block using J 38185. 4. Install the quick connect end of the outlet heater core hose (2) to the heater core. 5. Fill the engine cooling system. Refer to Draining and Filling Cooling System (Body Vin Code 3) in Cooling System. Body VIN 6 / GMT 370 HEATER HOSE REPLACEMENT - INLET (BODY TYPE VIN 6) TOOLS REQUIRED - J 43181 Heater Line Quick Connect Release Tool - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System (Body Vin Code 6) in Cooling System. 2. Remove the coolant recovery reservoir. 3. Using the J 43181 disconnect the inlet heater hose (2) from the heater core inlet tube. 3.1. Install the J 43181 to the quick connect on the outlet heater core hose (2). 3.2. Close the tool around the inlet heater core hose. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 4. Reposition the hose clamp at the engine outlet using J 38185. 5. Remove the heater inlet hose (4) from the the engine block. 6. Remove the nut retaining the coolant bypass valve to the cowl. 7. Remove the heater inlet hose. INSTALLATION PROCEDURE Page 9130 Page 245 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 9736 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Page 6470 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Page 10744 Install a new license plate pocket perimeter gasket onto the backside edge of the pocket housing as shown above, starting at the middle of the seal at the top center of the pocket. This will ensure that the seal will be even. When properly installed, there will be 25-50 mm (1-2 in) on either side of the liftgate release handle (2) that the seal (1) does not reach. DO NOT attempt to install the seal on the liftgate directly below the release handle. Install the license plate pocket assembly onto the liftgate. Refer to the License Plate Pocket Replacement procedure in the Body Rear End (2006 MY and prior) or Exterior Trim sub-section of SI. Modify the tightening sequence for the screws that retain the pocket assembly to the liftgate as follows: Push the entire rear license plate pocket assembly upward in the opening of the liftgate. Inspect the perimeter gasket to see if it is properly retained. Tighten Tighten the rear license plate pocket assembly retaining nuts to 5 N.m (44 lb in) in the following order. Tighten the upper left retaining nut first. Tighten the upper right retaining nut second. Tighten the three lower retaining nuts in any order. Parts Information Brakes - Park Brake Shoe Retaining Clip Kit Parking Brake Shoe: Technical Service Bulletins Brakes - Park Brake Shoe Retaining Clip Kit Bulletin No.: 02-05-26-001C Date: January 19, 2005 INFORMATION Subject: Rear Parking Brake Shoe Retaining Spring Clip Service Kit for Drum-in-Hat (DIH) Equipped Vehicles Models: 2004-2005 Buick Rainier 2002-2005 Cadillac Escalade Models 2002-2005 Chevrolet Avalanche 1998-2005 Chevrolet Blazer 1999-2005 Chevrolet Silverado Models 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet SSR, TrailBlazer Models 2003-2005 Chevrolet Astro, Express 1998-2005 GMC Jimmy 1999-2005 GMC Sierra Models 2000-2005 GMC Yukon Models 2002-2005 GMC Envoy Models 2003-2005 GMC Safari, Savana 1998-2004 Oldsmobile Bravada This Bulletin ONLY applies to 1500 series vehicles with four wheel disc brakes. Supercede: This bulletin is being revised to include additional models and clarify parts usage information. Please discard Corporate Bulletin Number 02-05-26-001B (Section 05 - Brakes). A rear parking brake retaining spring clip kit has been released for service. This kit consists of two parking brake hold down spring clips (2) and bolts (3). Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface, it may damage the rotor surface. During rear brake rotor removal, it is possible to damage the parking brake shoe retaining spring clip. Order this new kit when replacement of the clips is required but the parking brake shoes do not require replacement. Page 2474 started. Page 22 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 863 Abbreviations And Meanings Part 8 Page 13036 7. Using your finger, remove the socket retaining ring by pulling the retaining ring out of the mounting hole. INSTALLATION PROCEDURE 1. Position the retaining ring to the mounting hole. 2. Index the key to the retaining ring to the slot in the mounting hole. 3. Install the retaining ring by pressing the retaining ring into the mounting hole until fully seated. 4. Connect the electrical connector to the socket. 5. Position the socket to the retaining ring. 6. Install the socket into the retaining ring by pressing in the socket until fully seated. 7. Install the 12 volt power supply or cigar lighter fuse. Page 8664 Housing Assembly HVAC: Service and Repair HVAC Module Case Sump - Auxiliary HVAC MODULE CASE SUMP REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Remove the evaporator core-auxiliary. 2. Remove the HVAC module-auxiliary case sump (4) from the HVAC module. INSTALLATION PROCEDURE 1. Install the HVAC module-auxiliary case sump (4) to the HVAC module. 2. Install the evaporator core-auxiliary. Page 12055 WA526F/72 - WA528F/76 Page 3916 Abbreviations And Meanings Part 3 Page 9627 Page 2256 Application Table Part 2 Page 243 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 13127 English Prevailing Torque Fastener Minimum Torque Development Part 2 ENGLISH PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Thread Inserts THREAD INSERTS General purpose thread repair kits. These kits are available commercially. Repair Procedure 1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required Page 9625 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 56 Contract your dealer directly for more information. Abbreviations And Meanings ABBREVIATIONS AND MEANINGS Abbreviations And Meanings Part 1 Page 7161 9. Install the 3 bolts (1) that retain the junction block to the block base. Tighten Tighten the 3 bolts to 3.5 N.m (31 lb in). 10. Install the BCM to the rear electrical center. 11. Install the battery feed terminal nut (2) to the junction block. Tighten Tighten the battery feed terminal nut to 10 N.m (88 lb in). 12. Install the rear electrical center cover. 13. If replacing the rear electrical center on a Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada, position the left second row seat to a passenger position. 14. If replacing the rear electrical center on a Chevrolet TrailBlazer EXT or GMC Envoy XL, install the left second row seat. 15. Connect the battery negative cable. Page 10376 Registered And Non-Registered Trademarks Part 3 Page 945 Powertrain Control Module (PCM) C1 Part 5 Page 7776 The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 2. Turn the steering wheel so that the front wheels are pointing straight ahead. 3. Turn the ignition switch to the lock position and remove the key. 4. Lock the steering column through the access hole in the lower steering column trim cover using the J 42640. 5. Raise and support the vehicle. 6. Disconnect the upper intermediate shaft boot from the lower intermediate shaft boot to gain access to the upper intermediate shaft to lower intermediate pinch bolt. 7. Remove the lower intermediate shaft to upper intermediate shaft pinch bolt. 8. Disconnect the lower intermediate shaft from the upper intermediate shaft. 9. Lower the vehicle 10. Attempt to duplicate the customer's concern again. ^ If the noise is still present with the intermediate shaft disconnected, DO NOT replace the intermediate shaft. ^ If the noise is not present, continue with the next step. 11. Raise and support the vehicle. Page 1523 40.1. Install the ring terminal (black wire) to ground G103 (1), located on the right side inner tender. 40.2. Route the pump wiring harness along the existing right side forward lamp harness. 40.3. Connect the electrical connectors to the coolant bypass valve (1) and auxiliary heater pump (2). 40.4. Position the relays onto the inner wheelhouse panel near the rear of the engine compartment. Page 2958 Registered And Non-Registered Trademarks Part 4 Page 5218 Case: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Page 12152 Metric Prevailing Torque Fastener Minimum Torque Development Part 2 METRIC PREVAILING TORQUE FASTENER MINIMUM TORQUE DEVELOPMENT Page 568 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Page 12539 Abbreviations And Meanings Part 7 Page 7095 Multiple Junction Connector: Diagrams C301 - C316 C301 Part 1 Locations Power Seat Page 10058 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 6809 Abbreviations And Meanings Part 13 Page 10209 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 13122 A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive(r) or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive(r) recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. Fastener Strength Identification The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: Lower strength - No numbered head marking system - Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: M6.0 X 1 Page 10340 Conversion - English/Metric Part 3 Special Tools and Ordering Information SPECIAL TOOLS AND ORDERING INFORMATION The special service tools shown have product numbers beginning with J, SA or BT are available for worldwide distribution from: Monday through Friday 8:00 AM-7:00 PM Eastern Standard Time The TECH 2 scan tool and accessories can be purchased through: Monday through Friday 8:00 AM-6:00 PM EST Diagnostic Work Sheets DIAGNOSTIC WORK SHEETS The GM Diagnostic Worksheet has been designed to improve communications between the service customer and the technician. The diagnostic worksheet can provide the technician with more information than the conventional repair order, since it is filled out by the service customer. The GM Diagnostic Worksheets are available to you at no cost. The GM Diagnostic Worksheet is available in pad form from Reynolds & Reynolds at 1-800-344-0996. Fasteners FASTENERS METRIC FASTENERS This vehicle is dimensioned in the metric system. Most metric fasteners are very close in diameter to well known fasteners in the English, inch system. Replace fasteners with those of the same nominal diameter, thread pitch, and strength. Page 12009 WA253A/86 - WA379E/86 Lighting - Turn Signal Flasher Sticks ON Turn Signal Flasher: All Technical Service Bulletins Lighting - Turn Signal Flasher Sticks ON Bulletin No.: 03-08-42-014 Date: December 09, 2003 INFORMATION Subject: New Turn Signal Flasher Module Availability Models: 2004 Buick Rainier 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003 Chevrolet SSR - Built Prior to VIN Breakpoint 3B101657 2003-2004 GMC Envoy, Envoy XL 2004 GMC Envoy XUV 2003-2004 Oldsmobile Bravada Built After April 2003 New Flasher Module Availability Important: Always use the part number listed in the table below for flasher replacement on the above vehicles. The factory installed Turn Signal Flasher Module in the vehicles listed above has been superseded by a revised part number. Do not use the original flasher module part number if a replacement is needed. An anomaly has been observed in the original production flasher that could cause the flasher module to stick in the "on" position if the directional signal is used for an extended period of time. Always use the part number listed in the table below for flasher replacement on the above vehicles. Parts Information Parts are currently available from GMSPO. Disclaimer Page 6965 Fuse Block - Rear C4 Part 4 Fuse Block - Underhood C1 Fuse Block - Underhood C1 Part 1 Page 9519 Page 4025 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6959 Fuse Block - Rear C2 Part 7 Fuse Block - Rear C3 Part 1 Page 11910 Disclaimer Page 13436 Page 13091 Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Page 9782 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 11714 1. Remove the front and rear door sill plates. 2. Move the seat to a forward position. 3. Release the 4 retaining clips that attach the garnish molding to the center pillar. 4. Disconnect the electrical connector from the temperature sensor, if equipped. 5. Remove the garnish molding from the vehicle. Installation Procedure 1. Position the garnish molding to the center pillar. 2. Connect the electrical connector to the temperature sensor, if equipped. 3. Index the positioning tabs on the garnish molding to the corresponding holes in the center pillar. 4. Seat the 4 garnish molding retaining tabs to the center pillar. 5. Return the seat to neutral position. 6. Install the front and rear door sill plates. Garnish Molding Replacement - Rear Window Garnish Molding Replacement - Rear Window Removal Procedure 1. Open the liftgate. 2. Release the clips that retain the garnish molding to the liftgate. 3. Remove the wire harness (1) from the slot located on the garnish molding. 4. Remove the garnish molding from the liftgate. Installation Procedure Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Page 1122 Lumbar Adjuster Switch - Passenger (w/o Heat) Page 11788 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction Data is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Page 6184 - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). Page 8156 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 8918 Locations View Page 2045 16. Connect the power steering hose assembly to the power steering gear. 17. Install the power steering hose assembly to power steering gear retaining bolt. Tighten the power steering hose assembly to power steering gear retaining bolt to 12 Nm (106 inch lbs.). 18. Remove the drain pan from under the vehicle. 19. Lower the vehicle. 20. Bleed the power steering system. Page 233 Page 8146 Disclaimer Page 3351 Radiator Cap: Testing and Inspection Pressure Cap Testing ^ Tools required ^ J24460-01 Cooling System Pressure Tester ^ J 42401 Radiator Cap / Surge Tank Test Adapter Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. 3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. 4. Test the pressure cap for the following conditions: ^ Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. ^ Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: ^ The pressure cap does not release pressure which exceeds the rated pressure of the cap. ^ The pressure cap does not hold the rated pressure. Page 2914 Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. Page 6653 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 12328 Head Restraint Guide Assembly Replacement - Rear No. 2 HEAD RESTRAINT GUIDE ASSEMBLY REPLACEMENT - REAR NO. 2 REMOVAL PROCEDURE 1. Remove the head restraint assembly. 2. Remove the seat back cover and pad to expose the seat back frame. 3. Gently pull the pad away from the seat back frame. It may be glued in places from its original assembly. 4. Remove the head rest restraint guides by squeezing the tabs on the bottom of the guide together and pulling the guide upward out of the seat. INSTALLATION PROCEDURE 1. Install the head restraint guides by pushing them through the cover into the frame until the locking tabs snap into place. The guide with the locking tab (1) installs on the right hand side of the seat. 2. Install the seat back cover and pad on the seat back frame. 3. Install the head restraint assembly. Page 5740 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Page 3029 Timing Cover: Service and Repair Engine Front Cover Replacement - Tools Required J 44219 Cover Alignment Pins Removal Procedure 1. Drain the engine coolant. 2. Remove the cooling fan and the shroud. 3. Remove the drivebelt. 4. Remove the water pump. 5. Remove the crankshaft balancer. 6. Remove the power steering pump. 7. Raise the vehicle. Refer to Vehicle Lifting. 8. Remove the oil pan. 9. Lower the vehicle. 10. Remove the 7 mm center bolt (1). 11. Loosen and remove the remaining engine front cover bolts. 12. Place two of the front cover bolts in the jack screw holes on the front cover and tighten the bolts evenly to release the front cover from the engine. 13. Remove the two bolts from the front cover. 14. Remove the oil pump. 15. Clean and Inspect the front cover. Installation Procedure 1. Install the J 44219, onto the engine. Specifications Ball Joint: Specifications Lower Ball Joint Retaining Nuts ............................................................................................................................................................. 110 Nm (81 ft. lbs.) Upper Ball Joint Pinch Bolt .................................................................................. .................................................................................... 40 Nm (30 ft. lbs.) Page 2915 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 625 Mirror Connector, Driver Door Module (DDM) - C3 Part 1 Page 4289 Abbreviations And Meanings Part 23 Locations Hazard Switch Page 9535 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 7244 TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction Data The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 11525 1. Install the transmission support to the frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper transmission support to the frame mounting bolts. Tighten the upper transmission support to the frame mounting bolts to 80 N.m (59 lb ft). 3. Install the lower transmission support to the frame mounting bolts. Tighten the bolts to 50 N.m (37 lb ft). 4. Lower the transmission onto the transmission support. 5. Install the transmission mount to the transmission support retaining nuts. Tighten the transmission mount to the transmission support retaining nuts to 46 N.m (35 lb ft). 6. Install the evaporative emission (EVAP) canister. 7. Install the fuel tank shield. 8. Lower the vehicle. Page 1630 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Remove the harness connector. 2. Remove the bolt (2). 3. Remove the vehicle speed sensor (1). 4. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) on the vehicle speed sensor (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the vehicle speed sensor (1) into the transmission case. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 5. Connect the wiring harness electrical connector to the vehicle speed sensor. 6. Refill the fluid as required. Page 10851 5. Tape over the entire cable. Use a winding motion when you apply the tape. Page 1711 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 6642 Page 10650 Page 8257 6. Install the right rear quarter trim panel. Replacement - Auxiliary (Upper) AIR DISTRIBUTION DUCTS REPLACEMENT - AUXILIARY (UPPER) REMOVAL PROCEDURE 1. Remove the right rear quarter trim panel. 2. Remove the headliner. 3. Remove the mid upper air distribution duct retaining fastener (7). 4. Remove the mid upper air distribution duct (6) from the C-pillar. 5. Remove the lower air distribution duct (5) from the C-pillar. INSTALLATION PROCEDURE 1. Install the lower air distribution duct (5) to the C-pillar. 2. Install the lower air distribution duct retaining screw (4). 3. Tighten the lower air distribution duct retaining screw. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings Tighten Tighten the screw to .....1.9 N.m (17 lb in). 4. Install the upper air distribution duct (6) to the C-pillar. 5. Install the upper air distribution duct retaining screw (7). Tighten Tighten the screw to .....1.9 N.m (17 lb in). Page 8335 Page 9149 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Page 4147 Registered And Non-Registered Trademarks Part 7 Listed are Registered Trademarks ((R)) or Non-Registered Trademarks ((TM)) which may appear. Page 7493 C314 Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear bumper fascia. 2. Using a small flat-bladed tool, apply pressure at two upper locations and two lower locations to release the retainers on the pressure relief valve. 3. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Install the rear bumper fascia. Page 10322 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Page 4280 Abbreviations And Meanings Part 14 Page 10730 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 9652 Recall - Spark Plug Misfire Condition Spark Plug: All Technical Service Bulletins Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the A/C - Slow to Cool in Hot/Humid Conditions Fan Clutch: Customer Interest A/C - Slow to Cool in Hot/Humid Conditions Bulletin No.: 04-01-38-019A Date: June 07, 2005 TECHNICAL Subject: Intermittent Slow to Cool HVAC Performance Concerns in High Ambient Temperatures and/or High Humidity Conditions After Start Up, Especially at Low Engine Speeds (Install New Engine Cooling Fan Clutch) Models: 2004-2005 Buick Rainier 2002-2005 Chevrolet TrailBlazer Models 2002-2005 GMC Envoy Models 2002-2004 Oldsmobile Bravada 2005 Saab 9-7X Supercede: This bulletin is being revised to provide repair information for this customer concern. Please discard Corporate Bulletin Number 04-01-38-019 (Section 01 - HVAC). Condition Some customers may comment on slow to cool Air Conditioning (A/C) performance or high A/C outlet temperatures after start up or that the A/C system is not cooling sufficiently, especially in high ambient temperatures. This may be an intermittent condition and the performance of the Heating, Ventilation and Air Conditioning (HVAC) system may not meet customer expectations. Cause This condition may be caused by the response of the Electro-Viscous (EV) fan clutch and can be related to airflow across the condenser. This low A/C system performance can occur for longer periods of time if the vehicle is allowed to idle or is driven in low speed conditions. The response of the EV fan clutch will affect A/C system performance. As higher road speeds are attained, the increased airflow across the condenser will usually improve A/C system performance and the response of the EV fan clutch. This condition may be more evident after the vehicle has set for a period of time and can be difficult to duplicate. The condition may occur after the vehicle has set for as little as 10 minutes or as long as overnight. It is most prevalent intermittently during the first 15 minutes of operation. Correction Technicians are to replace the EV fan clutch with a new design part, P/N 15293048, on vehicles built before June 2005. Vehicles built in June 2005 may already have the updated EV fan clutch and it will not need to be replaced. For 2004 model year vehicles and older, update the Powertrain Control Module (PCM) with a software calibration that was developed to improve coolant temperature gauge readings. This new calibration will cause the PCM to command small amounts of additional fan engagement to better control engine coolant temperatures. Model year 2005 vehicles already have this calibration installed. Refer to Corporate Service Bulletin Number 04-06-02-005 for more information about this calibration. Proper diagnosis of any customer concern is essential. Refer to the Diagnostic Starting Point-Heating, Ventilation and Air Conditioning procedure in SI to begin a diagnosis of any HVAC concerns. Refer to the Diagnostic Starting Point-Engine Cooling procedure in SI to begin a diagnosis of any engine cooling or engine cooling fan concerns. If an attempt is made to diagnose an HVAC system concern, all parameters must be measured. As an example, both the low and high side refrigerant pressure readings must be measured. If only the low side pressure readings were measured, it would appear that the A/C compressor is disengaging at a higher pressure than expected. If both the low and high side pressures were being measured, it would be noted that the A/C compressor is probably disengaging due to the maximum high side pressure cut out point being reached. This occurs to protect the HVAC system from damage. The updated PCM software calibration along with the updated EV fan clutch will improve this condition due to increased air flow across the condenser. The new EV fan clutch has an increased minimum operating fan speed and an improved response time. Additional engine cooling Page 4353 Powertrain Control Module (PCM) C1 Part 2 Page 6692 Abbreviations And Meanings Part 14 Page 12467 4. Release the J strips (1,3) on each side of the seat cushion. 5. Release the front/rear J strips (2,4). 6. Remove the SIR electrical harness (2) from the seat pan. 7. Remove the seat electrical harness from the seat pan. 8. Remove the wire harness fasteners from the seat pan. 9. Disconnect the seat cushion heater electrical connector, if equipped. Important: When separating the seat cover hook and loop retaining strips, do not pull the adhesive-backed strip from the seat pad. 10. Separate the hook and loop retaining strips. 11. Remove the hog rings (1) from the bottom rear side of the cover. 12. Remove the 11 hog rings from the top side of the cover. 13. Remove the seat cushion trim cover and pad from the seat frame. 14. Remove the seat module retaining screw, if equipped. 15. Remove the seat module, if equipped. 16. Remove the seat cover from the seat cushion. 17. Remove the seat cushion from the seat pan. Installation Procedure 1. Install the seat cushion to the seat pan. 2. Install the seat cover to the seat cushion. 3. Using a side to side motion, carefully pull the seat cushion cover onto the seat pan. Page 1704 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 1276 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the A/C low pressure switch electrical connector. 2. Remove the A/C low pressure switch (2) from the accumulator (1). 3. Remove and discard the O-ring seal from the A/C low pressure switch port on the accumulator. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the A/C low pressure switch (2) to the accumulator (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Heating and Air Conditioning/Service Precautions/Vehicle Damage Warnings Tighten Tighten the A/C low pressure switch to 4.8 N.m (42 lb in). 3. Connect the A/C low pressure switch electrical connector. 4. Leak test the fittings of the components using the J 39400-A. Page 10428 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 8905 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module yellow 4-way connector (1) located behind the main IP support. 3. Install the CPA to the IP module yellow 4-way connector (1) located behind the IP support. 4. Install the SIR fuse to the fuse block (1) located in the underhood fuse block. 5. Staying well away from all air bags, turn ON the ignition, with the engine OFF. 5.1. The AIR BAG indicator will flash 7 times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform the Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 1. Remove the key from the ignition. Page 7357 Fuse Block - Underhood C3 Part 3 OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 10551 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Diagram Information and Instructions Generator: Diagram Information and Instructions Utility/Van Zoning UTILITY/VAN ZONING Page 7998 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the ABS sensor mounting bolt from the wheel hub and bearing. 5. Remove the ABS sensor from the wheel hub and bearing. 6. Remove the wheel hub and bearing to the steering knuckle mounting bolts. 7. Remove the wheel hub and bearing from the steering knuckle. 8. Remove the splash shield from the steering knuckle. Page 5465 1. Install a new seal (2) into the transmission case. 2. Install the filler tube (1) into the seal. 3. Remove the drain pan. 4. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the nut (2) securing the filler tube to the exhaust manifold stud (1). ^ Tighten the nut to 10 Nm (89 inch lbs.). 6. Install the filler tube indicator. 7. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Page 2824 Abbreviations And Meanings Part 22 Page 6955 Fuse Block - Rear C2 Part 3 Page 8067 Disclaimer Page 2832 Registered And Non-Registered Trademarks Part 4 Page 2221 Fuse Block - Rear C2 Part 6 Page 6165 Page 502 3. Install the quick connector to the VCIM. 4. Install the remaining electrical connectors to the VCIM. 5. Install the VCIM (1) to the bracket. 6. Ensure the retaining tab (1) is fully seated. Powertrain Control Module (PCM) C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Powertrain Control Module (PCM) C1 Part 1 Page 7432 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 13465 Tighten the two screws to 2.5 N.m (22 lb in). Clean the application area of the CHMSL applique with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984 or equivalent, and dry thoroughly using a clean low lint towel or towelette. Apply double-sided adhesive tape, 3M(R) P/N 06397 or equivalent, to the underside of the CHMSL applique. Remove the old adhesive from the liftgate glass. The installation area of the liftgate glass must be clean and dry. Any airborne dust, oils, etc., may contaminate the glass or the applique adhesive, and reduce the bond of the tape. DO NOT use commercial glass or surface cleaners. These may contain petroleum. The glass surface temperature should be no lower than 21°C (70°F) and not exceed 38°C (100°F). Clean the application area of the liftgate glass with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984 or equivalent, and dry thoroughly using a clean low lint towel or towelette. Apply adhesive promoter, P/N 12378555 (in Canada, use P/N 88901239), to the liftgate glass surface, completely wetting the applique application area. Use a clean low lint towel or towelette and wipe the glass, only removing the excess adhesive promoter from the liftgate glass. Do not wipe the glass dry. Allow the liftgate glass to air dry completely. The applique must be installed within 30 minutes following the use of the promoter. Allow the adhesive promoter to remain on the glass surface for a minimum of 10 seconds. Attach the CHMSL wire to the connector and install the grommet. Slide the liftgate glass on the hinge pins to the left in order to allow clearance for the locating hooks. Remove the protective liner from the tape on the applique. Attach the locating hooks on the applique to the hinge pins. Apply the applique to the liftgate glass. With the heel of your hand, and starting from center of the applique and working outward towards each outer edge, apply even and consistent pressure insuring complete contact of the adhesive strip to the glass. Install the screws that retain the applique to the liftgate glass. Tighten Tighten the screws to 5 N.m (44 lb in). The vehicle must be kept dry and at 21°C (70°F) to 43°C (110°F) for no less than 4 hours to ensure proper adhesive cure time. Clean the liftgate glass and applique area. Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Vacuum Brake Booster Check Valve and/or Hose Replacement Removal Procedure 1. Remove the vacuum brake booster check valve from the vacuum brake booster. 2. Remove the vacuum brake booster hose clamp at the check valve. 3. Remove the vacuum brake booster check valve from the hose. 4. Disconnect the vacuum brake booster hose at the engine. 5. Remove the vacuum brake booster hose from the vehicle. Installation Procedure 1. Connect the vacuum brake booster hose at the engine. 2. Install the vacuum brake booster check valve to the hose. 3. Install the vacuum brake booster hose clamp to the check valve. 4. Install the vacuum brake booster check valve to the vacuum brake booster. Specifications Crankshaft Seal Retainer: Specifications Crankshaft Rear Housing Bolt 89 inch lbs. Page 9909 Page 6649 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Page 9615 Page 8115 Disclaimer Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set Four Wheel Drive Selector Switch: Customer Interest Drivetrain - 'Service 4WD' Indicator ON/DTC B2725 Set File In Section: 04 - Driveline Axle Bulletin No.: 02-04-21-002A Date: February, 2003 TECHNICAL Subject: "Service 4WD" Indicator Illuminated, DTC B2725 Set, Transfer Case Selector Switch is in One Position - Indicator Lamp Indicates Another Range is Selected (Replace Transfer Case Shift Control Switch) Models: 2002-2003 Chevrolet TrailBlazer, TrailBlazer EXT 2002-2003 GMC Envoy, Envoy XL with Four-Wheel Drive This bulletin is being revised to change the part number, service procedures and a labor operation number. Please discard Corporate Bulletin Number 02-04-21-002 (Section 04 - Driveline Axle). Condition Some customers may comment that the Service 4WD indicator is illuminated or that the Indicator lamp is illuminated for a range other than the one selected with the selector switch. Upon investigation, the technician may find a DTC B2725. Cause The condition may be due to the transfer case shift control switch. Correction Replace the transfer case shift control switch using the applicable procedure below for the vehicle being serviced. GMC Envoy, Envoy XL Notice: Trying to remove the transfer case control switch from the instrument panel (IP) trim panel without releasing the retainers will damage the IP trim panel. The switch cannot be removed without first removing the trim panel. 1. Remove the four screws that retain the center IP closeout to the bottom of the IP. The closeout is located just in front of the floor console assembly with two (2) screws on each side. 2. Gently disconnect the trim panel from the IP by grasping the rearward portion of the closeout and pull toward the door openings. With the panel wings spread away from the IP, gently pull the panel wings down toward the footwell area of the vehicle. The front edge of the trim panel will drop down, allowing access to the two (2) screws retaining the lower edge of the IP trim panel. 3. Place a clean shop cloth over the front edge of the console upper trim panel to protect against possible marring from the screwdriver. 4. Remove the two (2) screws. 5. Remove the center IP trim panel by gently pulling it toward the rear of the vehicle in order to release the retaining clips. 6. Disconnect the electrical connectors from the switch. 7. Depress the switch retainers and remove the switch. 8. Insert the new switch into the IP trim panel and reconnect the electrical connector. 9. Reinstall the IP trim and the two (2) retaining screws. 10. Reposition the closeout panel and install the four (4) retaining screws. 11. For 2002 vehicles produced prior to January 2002, verify that the vehicle contains the latest calibration for the automatic transfer case control module. The calibrations were available from Techline starting January 2002, on the TIS 2000 version TIS 01/2002 data update or later. Page 12444 4. Install the seat module, if equipped. 5. Install the seat module retaining screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 5 N.m (44 lb in). 6. Install the 11 hog rings to the top side of the cover and pad. 7. Install the 2 hog rings (1) to the bottom rear side of the cover and pad. 8. Press the seat cover hook and loop retaining strips together by running your hand firmly over the seat cover. HVAC System - Manual Blower Motor Switch: Service and Repair HVAC System - Manual FRONT AUXILIARY BLOWER MOTOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Press downward and to the right on the front auxiliary blower motor switch. 2. Remove the front auxiliary blower motor switch from the console. 3. Disconnect the electrical connector from the front auxiliary blower motor switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the front auxiliary blower motor switch. 2. Install the front auxiliary blower motor switch to console. 3. Press the front auxiliary blower motor switch into the console. Page 3529 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data from the driver door module (DDM), Passenger door module (PDM) and the liftgate module (LGM) and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Page 8324 40.5. Route the other end of the harness along the rear of the engine compartment to the left side and secure to the cross bar and dash panel with tie straps. Page 6364 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure Page 9874 4. Install the protective cover to the module. 5. Position the right rear seat bottom to a passenger position. 6. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 7. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 8. Use the ID information menu on the scan tool to access the new station ID (STID) and the electronic serial number (ESN) from the new VCIM. 9. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center and perform the following procedure: 9.1. Tell the advisor that this vehicle has received a new VCIM. 9.2. Ask the advisor to add the new STID and the ESN to update the customer's account. 9.3. Follow any additional instructions from the OnStar(R) advisor. 9.4. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available.